Solids removal system and method

ABSTRACT

The system and method is directed to improved separation or clarification of solids from a solids-laden liquid, including the removal of low gravity solids. A liquid to be treated is introduced into the inlet of a solid-liquid separator modified to include one or more sources of vibrational energy. The liquid is directed through a conduit within the separator. This conduit can be configured into a tortuous flow path to assist in the separation of solids from the liquid, the tortuous path being interconnected between two separation towers. Vibrational energy and gas sparging is applied to the flow path. As solids fall out of solution, they are collected. The clarified liquid is also collected. A vacuum can be applied to the system to assist in moving the solid-liquid mixture through the system and to provide vacuum clarification. Electrocoagulation electrodes can also be employed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Nonprovisional patentapplication Ser. No. 13/239,338 filed Sep. 21, 2011, now U.S. Pat. No.8,691,097, which is a continuation-in-part of U.S. Nonprovisional patentapplication Ser. No. 12/888,329 filed on Sep. 22, 2010, now U.S. Pat.No. 8,337,706, which in turn is a continuation-in-part of U.S.Nonprovisional patent application Ser. No. 12/250,535 filed on Oct. 13,2008, (now abandoned), which in turn claims the benefit of the filingdate of and priority to U.S. Provisional Application Ser. No. 60/979,858entitled “Solids Removal System and Method” and filed Oct. 14, 2007. Thecontents of said applications are incorporated by reference herein intheir entireties.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention is directed generally to a method and apparatusfor removing solids from a solid-liquid mixture, as well as the removalof entrained gasses. Example solid-liquid mixtures include, e.g.,drilling mud used in the oilfield industry, sewage, coal slurries,mining wastes, feed water for industrial applications, and othermixtures desired to be clarified. By way of one example, the method andapparatus of the present invention could be used alone or in combinationwith de-silters, de-sanders, de-gassers, shakers and shaker screens,and/or centrifuges used to treat drilling fluids in an oil fieldapplication.

The present invention is also directed to an apparatus and method(either as fixed installations, or as mobile systems for rapiddeployment) for removal of low gravity solids (LGS) and low gravitycolloidal material from liquids, such as, for example, drilling fluids,oil-base drilling fluids (mud), water-base drilling fluid (mud), andother liquids containing LGS or low gravity colloidal material. Thesystems and methods of the present invention can also be employed invarious additional applications, including, for example and withoutlimitation, treatment/separation of supersaturated brines, oil- orbunker fuel-contaminated water (fresh and sea water), offshore oil spillcleanup, slurrified contaminated soils, contaminated liquids, septicsystem fluids, environmental remediation, including onshore pipelineruptures where contaminated soil must be cleaned, containment pondcleanups, and oil-contaminated sand (e.g., from oil spills contaminatingthe beach sand).

BACKGROUND ART

As described in the Applicant's commonly owned U.S. Pat. No. 5,741,426,which is incorporated herein by reference in its entirety, there isdescribed a method and apparatus for treatment of contaminated water,containing undesired solid, liquid, and/or gaseous materials whichincludes an electro-floculation means for disassociating ions from theundesired solid material and from the contaminated water, and furtherincludes a separation tower having various deflection means deflectingundesired solid materials downwardly through the separation tower.

The Applicant's U.S. Pat. No. 5,741,426 also teaches the use of anupward tortuous or serpentine flow path in a vacuum-assistedseparator/clarifier to aid in the separation of solids from thesolid-liquid mixture passing therethrough. As such, it would bedesirable to further enhance the solids separation achieved from thesolid-liquid mixtures passing through a separator of the type describedin Applicant's U.S. Pat. No. 5,741,426. It would also be desirable toenhance the separation of the solids from the liquids present in othermechanical solid-liquid separation units.

Additionally, in the oil and gas industry, the use of oil-based drillingfluids and water-based drilling fluids is commonplace as part of thedrilling process. However, during use, these drilling fluids canaccumulate a build-up of low gravity colloidal materials, or low gravitysolids (LGS) that can impart negative qualities to the drilling fluid.These colloidal materials or LGS are a product of the drilling operationwhere the drill bit grinding against the rock creates these micro fine,typically insoluable, solids particles along with the rest of the drillcuttings. Low-gravity solids are sometimes referred to as a type ofdrilling-fluid solid having a lower density than the barite or hematitethat is used to weight up a drilling fluid, including drill solids plusthe added bentonite clay. The mud engineer calculates the concentrationof these and other types of solids on the basis of mud weight, retortanalysis, chloride titrations and other information. Solids are reportedas lbm/bbl or vol. %. Water is 1.0, barite 4.20, and hematite 5.505g/cm³. Low-gravity solids are normally assumed to have a density of 2.60g/cm³.

In the oil and gas industry, low-gravity solids buildup is becoming anincreasing problem for operators. Therefore, it is desirable to removethese ultra-fine solids to reduce the amount of disposable drillingfluid and the expensive task of rebuilding new fluid. Conventionalsolids-control equipment and methods are limited in what they canremove, and presently cannot remove low-gravity solids smaller than 8 to10 microns that accumulate and degrade the performance of costly oil-and synthetic-base drilling fluids.

When drilling into the reservoir itself, the use of specially designedoil- or synthetic-base reservoir drill-in fluids (RDF) becomesincreasingly important. These fluids are designed to drill the reservoirzone with minimal damage while maximizing production of the exposedzones. To achieve these goals, the RDFs should not contain clays oracid-insoluble weight materials that might migrate into the formation,plugging pores. They should be formulated with breakable or acid-solubleviscosifiers and other materials that limit the fluid loss to theformation and ensure good cleanup. Finally, they should prevent claysfrom swelling and plugging the formation. Despite these cautions, solidscontained in the RDFs can plug formation pore throats and cause reducedpermeability and formation damage if those solids cannot be adequatelyremoved. Even with an aggressive, but conventional, solids-controlprocess, some solids and bridging agent particles can degrade and becomeso small as to slip through the solids-control devices. Often the sizedcalcium carbonate solids used for weight and bridging are ground down toless than 8-10 microns, too small for most solids-control equipment tocapture and remove.

As a consequence, the operator ends up with drilling fluids that arecontaminated and must be disposed of or diluted with new mud to createuseable product. Compliance with disposal regulations makes disposal asignificant and expensive problem. Conventional treatment teaches takingthese old muds and diluting them enough to reduce the concentration ofthe undesired LDS. However, the dilution process itself requires 3× to4× the fluid volume and therefore taxes the available capacities of amud plant, in addition to increasing costs associated with handling,transportation and storage. Dilution of mud also presents a virtuallyinsurmountable problem on offshore rigs where there typically does notexist sufficient excess fluid storage capacity. The only other solutionis to build new mud thereby increasing costs on two fronts—new mud, anddisposal of old mud. One such solution has been with M-I Swaco's(Schlumberger) “Reclaim” system that uses a chemically-enhanceddewatering technology using flocculants, surfactants, and other polymersin connection with the use of centrifuges to remove these fine solidsfrom oil- or synthetic-base drilling fluids. See, Cook, R., “Handlingthe low-gravity solids overload”, Sep. 1, 2010, OilOnline.com. However,there remains a need to provide technology capable of removing LGS froma solid/liquid mixture, such as a drilling fluid.

BRIEF SUMMARY OF THE INVENTION

To address the forgoing desires, the present invention teaches the useof one or more sources of vibration to enhance the solid-liquidseparation occurring in a solid-liquid separator system.

The present invention is directed to a method and apparatus for improvedseparation or clarification of solids from a solids-laden liquid. Aliquid to be treated is introduced into the inlet of a solid-liquidseparator modified to include one or more sources of vibrational energy.The liquid to be treated is directed through a conduit within theseparator. Preferably the conduit within the separator is configuredinto a tortuous flow path to assist in the separation of solids from theliquid. Vibrational energy is applied to the flow path, preferablythrough the flow path conduit. As solids fall out of solution, they arecollected. The clarified liquid is also collected. A vacuum can beapplied to the system to assist in moving the solid-liquid mixturethrough the system and to provide vacuum clarification.

For example, the separator unit depicted in Applicant's U.S. Pat. No.5,741,426 can be modified such that at least one source of vibration isapplied to the separator thereby enhancing the separation of the solidsfrom the solid-liquid mixture passing through the separator. Such sourceof vibration can be mounted on the exterior of the separator unit (orpotentially within the unit) so that the vibration passes into theinterior of the separator. For example, a vibrator motor could bemounted on the outside of the separator depicted in Applicant's U.S.Pat. No. 5,741,426 so that the vibration passes into thebaffle/deflection plates forming the generally serpentine flow path. Thevibration can be created by any available source, such as, mechanical,electrical, air-driven, or hydraulic-driven vibrator devices and/or bysonic waves, microwaves, or other source of vibration.

In one preferred embodiment, the solids elimination system of thepresent invention consists of a square, rectangular or round verticalvessel with slanted baffle plates designed to cause a tortuous flow pathfor the solids laden liquid inside of the vessel. The system preferablyhas a vacuum apparatus to provide a lowered pressure or vacuum insidethe vessel. The lower pressure is regulated by a adjustable vacuumregulating valve located at the suction of the vacuum apparatus. Anotherapparatus is provided to remove the clean liquid (such as, drillingfluids) by means of a pump or other apparatus such as a liquid eductor.As the liquid phase is separated, the resulting solids laden slurry isremoved by a mechanical means such as a pump, augur, dump valve or othermeans. The liquid level is controlled by float switch or other liquidlevel control devices and a motor control flow valve.

Solids laden fluids, such as drill mud with solids entrained, are pulledinto the apparatus by means of the vacuum, through the inlet headerlocated at the top of the first slant plate. In one preferredembodiment, the first slant plate is made of thick plate and has avibrator motor attached to the bottom of the plate. A connecting rod canpreferentially be attached to each deflector and to the vibrator motorto distribute the vibration. The vibrator motor can also be set on topof the vessel and connected to each plate by means of the connectingrod. The vibrator motor can also be installed on the side of the vesselthereby having contact with the shell and all the baffle plates. Thevibration is designed to disturb the molecular bonding of the liquidsand the vibration amplification can be controlled by means of a V.F.D.(variable frequency drive) or other apparatus to change the rotationalspeed of the motor (and hence the vibration intensity). If a air orhydraulic vibrator device is used, the amplification can be controlledthrough pressure regulation or valve arrangements. If electric orelectronic vibration such as sonic or microwaves are used, theamplification can be adjusted by electronic means.

As the flow of solids laden liquid enters the inlet header it isdirected downward across the first vibrating plate. The vibrationapplied to the bottom plate disturbs the molecular bond of the liquidsand causes rapid settling of solid particulate matter. The downward flowalong with the vibration pushes the particulates to the lower edge ofthe slant plate where it is then directed into a standoff conduit. Theflow characteristics in the standoff conduit are such that the lack offlow does not keep the solid particulates entrained, but rather permitsthem to fall out to the bottom of the standoff conduit where they can bedischarged for further handling, disposal or use as may be desired.

The flow of the solid-liquid mixture to be treated is directed upwardlythrough a tortuous path caused by the baffle arrangement. As the solidsladen liquid moves upwards through this tortuous path, solids areseparated and fall into the standoff conduit thereby repeating theprocess until all undesirable particulate is removed. Entrained gasseswill also be released by the vibration and removed via the vacuumsource.

There is described a vacuum assisted solid-liquid separation apparatusfor treating contaminated liquids contaminated with undesired solids andgasses. In one embodiment, this apparatus has an enclosed separationtower having an upper end and a lower end opposite thereto, alongitudinal axis oriented substantially vertically through the upperend and the lower end, an outer wall, a top wall connected to the outerwall at the upper end and a bottom wall connected to the outer wallopposite the top wall, the outer wall having an inside surface and anoutside surface. The tower interior space defined as the space withinthe outer wall, top wall and bottom wall. The apparatus is outfittedwith a contaminated liquids inlet located proximate the vessel lower endfor introducing the contaminated liquids into the tower interior spaceand a clarified liquids outlet located above the contaminated liquidsinlet for discharging the clarified liquids to a desired location. Aplurality of baffle plates are disposed in the tower interior space in aspaced apart relationship, with at least some of the baffle plates beingangularly disposed with respect to the longitudinal axis of theseparation tower to define a generally serpentine fluid flow passageway,the serpentine fluid passageway having a first end in fluidcommunication with the contaminated liquid inlet, and a second end influid communication with the clarified water outlet and the towerinterior space proximate the upper end of the tower, the angulardisposition of the plates creating a series of alternating downwardlyand upwardly sloped flow segments within the serpentine first fluid pathwherein the contaminated liquid generally flows downwardly in each ofthe downwardly sloped segments into a downward slope corner and upwardlyin the upwardly sloped segment toward an upward slope upper corner.

One or more solids discharge ports are located in one or more of thedownward slope corners. A standoff conduit is provided in fluidcommunication with the one or more solids discharge ports for receivingsolids from the contaminated water through the one or more solidsdischarge ports, the standoff conduit having at its lower end a solidsoutlet port and its upper end being in fluid communication with thetower interior space. The apparatus also employs a vacuum inlet in fluidcommunication with the tower interior space and located above theclarified liquid outlet for pulling a vacuum on the tower interior spaceto urge contaminated liquid into the contaminated liquid inlet and upthrough the serpentine fluid flow passageway to the clarified liquidoutlet; and one or more sources of vibrational energy applied to theseparation apparatus.

The vibration energy sources are preferably created by mechanical,electrical, air-driven, or hydraulic-driven vibrator devices and/or bysonic waves, microwaves, or sources of vibration that provide forcontrol of the amplification of the vibration by means of a variablefrequency drive or other apparatus to change the intensity of thevibration. In one embodiment, a single source of vibrational energy isapplied to the separation apparatus; in another, more than one source ofvibrational energy is applied to the separation apparatus. The source ofvibrational energy may be directed to the plurality of baffle plates.The source of vibrational energy can be located on the bottom, topand/or side of the tower.

In another embodiment, the solid-liquid separation apparatus furthercomprises a connecting rod extending from the lower end of the tower andupward through the plurality of baffle plates, the connecting rod havinga first end located proximate one of the one or more vibrational energysources and a second end terminating either within the tower interiorspace or extending into the tower upper end. The connecting rod secondend can extend into the tower upper end and both ends of the connectingrod can receive a source of vibrational energy from the vibrationalenergy sources.

The solid-liquid separation apparatus tower can be substantiallycylindrical, rectangular or square in shape.

In one embodiment, the standoff conduit is located within the tower. Inanother embodiment, the standoff conduit is located external to thetower.

The solid-liquid separation apparatus can further comprise an inletcontrol valve for controlling the flow of contaminated liquid throughthe contaminated liquids inlet, a clarified liquid outlet control valvefor controlling the flow of clarified liquid through the clarifiedliquids outlet, a solids discharge control valve for controlling theflow of solids out of the standoff conduit and a liquid level controldevice for monitoring and controlling the liquid level in the tower. Aprocess controller can be employed to monitor and coordinate theoperation of the inlet control valve, the clarified liquid outletcontrol valve, the solids discharge control valve and/or the liquidlevel control device.

A pump can be connected with the solids outlet port to facilitateremoval of received solids from the standoff conduit.

In one embodiment, of the solid-liquid separation apparatus, theangularly disposed baffle plates are angularly disposed with respect tothe longitudinal axis of the separation tower between 1 and 45 degrees.In another embodiment, the angle is between 45 and 60 degrees.

In another embodiment, the separator device further comprises one ormore electrocoagulation electrodes housed within the serpentine fluidpassageway capable of discharging an electrical current into the fluid,wherein the electrodes are capable of alternating between a positivepolarity and a negative polarity and are controlled by process controlequipment.

There is also described a method of removing undesirable solids andgasses from liquid contaminants comprising the steps of: (a) directingsolids laden liquids into the inlet of a vacuum assisted solid-liquidseparation apparatus such as described herein for treating contaminatedliquids contaminated with undesired solids and gasses; (b) applying atleast one vibrational energy source to the separation apparatus; (c)applying a vacuum source at the vacuum inlet via the vacuum apparatus;(d) flowing the solids laden liquids from the inlet upwardly through thegenerally serpentine fluid flow passageway with the vacuum apparatus tocause undesired solid materials striking the baffle plates to bedirected downwardly into the standoff conduit toward the lower end ofthe separation tower; (e) removing clarified liquid from the separationtower through the clarified water outlet; (f) removing undesired gassesout through the vacuum apparatus; and (g) removing undesired solids fromthe standoff conduit. In embodiments using adjustable height weirs, themethod includes the additional steps of adjusting the effective weirheight to optimize operation.

The method can further comprise steps of monitoring and coordinating theoperation of the inlet control valve, the clarified liquid outletcontrol valve, the solids discharge control valve and/or the liquidlevel control device. The method can also include controlling theamplification or intensity of the vibration. In one embodiment of themethod, the vibrational energy is directed to the serpentine flowpathway.

Where the separator device employs electrocoagulation electrodes, themethod further comprises the step of introducing a current from theelectrodes into the serpentine fluid passageway, and alternating thepolarity of the electrodes between positive and negative polarity.

The solid-liquid separation apparatus may further comprise one or moregas spargers mounted within the serpentine fluid passageway in an areaabove the one or more solids discharge ports located in the one or moreof the downward slope corners for introducing a sparge gas into theserpentine fluid pathway. The method would also include the step ofintroducing said sparge gas into the serpentine fluid pathway.

The solid-liquid separation apparatus may further comprise a chemicalinjection port for introducing into the serpentine fluid path one ormore desired treatment chemicals, and the method would further comprisethe step of introducing the one or more chemicals into the serpentinefluid pathway.

In another embodiment of the present disclosure, there is described avacuum assisted solid-liquid separation apparatus for treatingcontaminated liquids contaminated with undesired solids and gasses,comprising: (a) an enclosed separation tower having an upper end and alower end opposite thereto, a longitudinal axis oriented substantiallyvertically through the upper end and the lower end, an outer wall, a topwall connected to the outer wall at the upper end and a bottom wallconnected to the outer wall opposite the top wall, the outer wall havingan inside surface and an outside surface; (b) a tower interior spacedefined as the space within the outer wall, top wall and bottom wall;(c) a contaminated liquids inlet located proximate the vessel lower endfor introducing the contaminated liquids into the tower interior space;(d) a clarified liquids outlet located above the contaminated liquidsinlet for discharging the clarified liquids to a desired location; (e) aplurality of baffle plates disposed in the tower interior space in aspaced apart relationship, with at least some of the baffle plates beingangularly disposed with respect to the longitudinal axis of theseparation tower to define a generally serpentine fluid flow passageway,the serpentine fluid passageway having a first end in fluidcommunication with the contaminated liquid inlet, and a second end influid communication with the clarified water outlet and the towerinterior space proximate the upper end of the tower, the angulardisposition of the plates creating a series of alternating downwardlyand upwardly sloped flow segments within the serpentine first fluid pathwherein the contaminated liquid generally flows downwardly in each ofthe downwardly sloped segments into a downward slope corner and upwardlyin the upwardly sloped segment toward an upward slope upper corner; (f)one or more solids discharge ports located in one or more of thedownward slope corners; (g) a standoff conduit, having upper and lowerends, in fluid communication with the one or more solids discharge portsfor receiving solids from the contaminated water through the one or moresolids discharge ports, the standoff conduit having at its lower end asolids outlet port, and having its upper end in fluid communication withthe tower interior space; (h) one or more upper discharge slots locatedin one or more of the upward slope upper corners; (i) a secondarystandoff conduit, having upper and lower ends, in fluid communicationwith the one or more upper discharge slots for receiving gasses, oils,bubbles and other lighter materials from the contaminated liquidsthrough the one or more upper discharge slots, the secondary standoffconduit having at its lower end a lower outlet for dischargingaccumulated solids, and having housed within its upper end an upperoutlet coupled with a weir for receiving oil and discharging oil out theoutlet into discharge tubing, the upper end of the secondary standoffconduit being in fluid communication with the tower interior space; (j)a vacuum inlet in fluid communication with the tower interior space andlocated above the clarified liquid outlet for pulling a vacuum on thetower interior space to urge contaminated liquid into the contaminatedliquid inlet and up through the serpentine fluid flow passageway to theclarified liquid outlet; and (k) one or more sources of vibrationalenergy applied to the separation apparatus. In other embodiments, thisdevice can employ electrocoagulation electrodes, gas sparging, and/orinjection of one or more chemical additives.

In another embodiment, the separation apparatus has a vacuumequalization conduit inlet in fluid communication with the towerinterior space and located above the clarified liquid outlet. In thisembodiment, the separation apparatus is also equipped with an oilaccumulator for collecting oil. The accumulator comprises an enclosedhousing having a top, a bottom, sidewalls and an inner chamber, anaccumulator oil inlet proximate or in the accumulator top. The dischargetubing is connected between the accumulator oil inlet and the secondarystandoff upper outlet, and places the accumulator inner chamber in fluidcommunication with the secondary standoff conduit. The accumulator alsoemploys a vacuum inlet proximate the accumulator top, a vacuum equalizerconduit connected between the accumulator vacuum inlet and the vacuumequalization conduit inlet, the equalizer conduit placing theaccumulator inner chamber in fluid communication with the tower interiorspace. The accumulator also uses an oil outlet located in or proximatethe accumulator bottom, an oil outlet conduit connected to the oiloutlet, an oil outlet control valve connected to the oil outlet conduitfor discharging oil from the accumulator through discharge conduit to adesired location. The control valve employs a one-way check valve on thedischarge side of the control valve. The accumulator may also beequipped with an upper liquid level control device within theaccumulator inner chamber to sense the liquid level and communicate withthe oil outlet control device, and a lower liquid level control devicewithin the accumulator inner chamber to sense the liquid level andcommunication with the oil outlet control device. The accumulator can besubstantially cylindrical, rectangular or square in shape.

In another embodiment of the present disclosure, the accumulatorcomprises a centrally-located vertical partition extending across theaccumulator internal chamber and upwardly in the chamber from theaccumulator bottom to a desired height within the chamber. The partitioncreates a lower right chamber and a lower left chamber. The accumulatoroil inlet is located proximate the right chamber to permit entry of oilfrom the weir to be directed into the right chamber. The oil collects inthe right chamber and is capable of spilling over the partition into theleft chamber. The left chamber oil outlet is located in or proximate theaccumulator bottom in the left chamber. The left chamber oil outlet isconnected to the oil outlet conduit. A right chamber outlet is locatedin or proximate the accumulator bottom in the right chamber. An outletcontrol valve is connected to the right chamber outlet conduit fordischarging contents from the accumulator right chamber throughdischarge conduit to a desired location. The control valve employs aone-way check valve on the discharge side of the control valve. Thelower liquid level control device is located within the accumulator leftchamber to sense the liquid level and for communication with the oiloutlet control device. A second lower liquid level control device islocated within the accumulator right chamber to sense the liquid leveland for communication with said right chamber outlet control valve.

The vacuum assisted solid-liquid separation apparatus of may alsoadvantageously employ a height adjustable weir. In one embodiment, theheight adjustable weir is a rotatably adjustable weir comprising aswivel joint mounted in-line of the discharge tubing proximate thesecondary standoff conduit upper outlet. The swivel joint is capable ofdirecting the discharge tubing upward at an angle ranging between about0 degrees and 90 degrees to create an increase in the effective weirheight as the tubing moves upward, and to create a decrease in theeffective weir height as the tubing moves downward. Preferably, thedischarge tubing is flexible. The swivel joint may be selected from thegroup consisting of manually operated swivel joints and automatic motordriven swivel joints.

In another embodiment, the height adjustable weir is a tubing heightadjustable weir comprising a moveable conduit guide movably mountedproximate the secondary standoff conduit upper outlet. The conduit guideis capable of securing the discharge tubing at desired heights relativeto the upper outlet to provide a desired effective weir height.Preferably, the discharge tubing is flexible.

In yet another embodiment, the height adjustable weir is a gate heightadjustable weir comprising: a weir housing having an internal weirairspace, an upper end, and a lower end. The weir housing is mounted insealed fashion on the exterior of the separator over the secondarystandoff conduit upper outlet. The upper outlet has an upper boundaryand a lower boundary. This weir embodiment also comprises a moveablegate mounted in a slot, the gate capable of being moved upwardly anddownwardly in the slot, the slot positioning gate proximate and belowthe upper outlet, the upward movement of the gate creating an increasein an effective weir height, the downward movement of the gate creatinga decrease in the effective weir height. A discharge conduit is attachedto the weir housing lower end, the discharge conduit being in fluidcommunication with the internal weir space. The gate height adjustableweir may be manually adjustable or may be automatically adjustable viamotorized operation and the like.

In the embodiments described herein, the use of the vacuum assistance isoptional. In any of the embodiments described herein, one or moresparging units may be used to provide microbubbles in the flow path(s).In further embodiments the fluids to be treated may optionally be heatedeither in a batch heating unit or an in-line heating unit beforeentering the separation device. Additionally, a pre-screening device canbe employed to remove large debris from the fluids prior to entering theseparation vessel.

In another embodiment, there is disclosed a separation apparatuscomprising three primary components: (a) a first separation tower, (b) asecond separation tower, and (c) a serpentine pathway interconnectingthe two towers. These three components may be integrated together into asingle unit. A vibrational source provides vibration to the unit. Spargegas is dispersed into the serpentine pathway and near the bottoms of thetowers to urge colloidal materials upwards for removal out of an exitlocated near the top water line of the towers. Solids are removed fromthe bottoms of the towers. The unit can be mounted on suitablevibrational dampening devices, or suspended from a frame. The towerscontain internal baffles. An upper conduit connects the two towers atthe waterline. A vacuum may optionally be applied. The contaminatedliquids may be pre-treated to remove large debris by passing the liquidsthrough suitable screening devices. The contaminated liquids may also beoptionally pre-heated. Electrocoagulation may also optionally beemployed. The contaminated fluids enter the serpentine path and come toa first downward turn (first serpentine segment). At this point islocated a sparger and fluids (and heavier solids) move downwardly. Alsoat this point is a slot to permit fluid flow into the first tower, nearthe upper portion thereof, where the sparge gas urges the lightmaterials, such as LGS or colloids, to migrate into the first tower. Atthe lower end of the first serpentine segment is an upward turn of thepassageway. At this point is also located a sparger. A slot is alsoformed leading into the lower section of the second tower to permitheavy solids to enter the lower end of the second tower. Fluids andlighter solids and colloidal materials are urged upward in the secondserpentine segment and exit into the upper portion of the first tower.Each tower is outfitted with vertical baffle plates mounted in amid-section of the tower to create vertical flow paths. Sparge units arealso located at the near the lower section of each tower to further urgecolloidals and LGS upwards on a bed of microbubbles. The colloids andLGS in the liquid of the second tower are carried to the top and flowover to the first tower via the upper conduit where they are dischargedout an upper outlet located along the waterline. Likewise, colloids andLGS in the first tower are urged upwardly on a bed of microbubbles andare discharged out the upper discharge. There is also a method oftreating liquids disclosed employing the this separation apparatus.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a partial cross-sectional view of one embodiment in accordancewith the present invention of an apparatus for treatment of contaminatedwater.

FIG. 1A is a partial cross-sectional view taken along line 1A-1A of FIG.1 depicting a separation tower embodiment having a cylindrical shape.

FIG. 1B is a partial cross-sectional view taken along line 1A-1A of FIG.1 depicting a separation tower embodiment having a rectangular shape.

FIG. 2 is a partial cross-sectional view of one embodiment in accordancewith the present invention of an apparatus for treatment of contaminatedwater.

FIG. 2A is a partial cross-sectional view taken along line 2A-2A of FIG.2.

FIG. 3 is a partial cross-sectional view of one embodiment in accordancewith the present invention of an apparatus for treatment of contaminatedwater.

FIG. 3A is a partial cross-sectional view taken along line 3A-3A of FIG.3.

FIG. 4 is a partial cross-sectional view of one embodiment in accordancewith the present invention of an apparatus for treatment of contaminatedwater.

FIG. 4A is a partial cross-sectional view taken along line 4A-4A of FIG.4.

FIG. 5 is a partial cross-sectional view of one embodiment in accordancewith the present invention of an apparatus for treatment of contaminatedwater.

FIG. 5A is a partial cross-sectional view taken along line 5A-5A of FIG.5.

FIG. 6 is a partial cross-sectional view of one embodiment in accordancewith the present invention of an apparatus for treatment of contaminatedwater.

FIG. 6A is a partial cross-sectional view taken along line 6A-6A of FIG.6 depicting a separation tower embodiment having a cylindrical shape.

FIG. 7 is a partial cross-sectional view of one embodiment in accordancewith the present invention of an apparatus for treatment of contaminatedwater.

FIG. 7A is a partial cross-sectional view of an accumulator according toone embodiment of the present invention.

FIG. 8A is a cross-sectional view of one embodiment of a heightadjustable weir, taken from view 8A-8E of FIG. 7, according to thepresent invention.

FIG. 8B is a cross-sectional view of another embodiment of a heightadjustable weir, taken from view 8A-8E of FIG. 7, according to thepresent invention.

FIG. 8C is a cross-sectional side view of yet another embodiment of aheight adjustable weir, taken from view 8A-8E of FIG. 7 according to thepresent invention, showing the weir gate in a lower position.

FIG. 8D is a cross-sectional side view of the height adjustable weir ofFIG. 8C, showing the weir gate in a raised position.

FIG. 8E is a cross-sectional front view of the height adjustable weir ofFIG. 8C, taken along lines 8E-8E.

FIG. 9 is a perspective side view of one embodiment in accordance withthe present invention of an apparatus for treatment of contaminatedliquids.

FIG. 10 is a side plan view of the embodiment of FIG. 9.

FIG. 11 is a left end plan view of the embodiment of FIG. 9.

FIG. 12 is a right end plan view of the embodiment of FIG. 9.

FIG. 13 is a top plan view of the embodiment of FIG. 9.

FIG. 14 is a partial side longitudinal cross-sectional view of FIG. 9.

FIG. 15A is a left end plan view of the embodiment of FIG. 14.

FIG. 15B is an enlarged view of area 15B from the embodiment of FIG.15A.

FIG. 16 is a partial side longitudinal cross-sectional view of FIG. 9.

FIG. 17 is a perspective view of a storage chamber.

FIG. 18 is a side plan view of the storage chamber of FIG. 17.

FIG. 19 is another side plan view of the storage chamber of FIG. 17.

FIG. 20 is a top plan view of the storage chamber of FIG. 17.

FIG. 21 is another side plan view of the storage chamber of FIG. 17.

FIG. 22 is a process flow diagram according to one embodiment of thepresent invention.

FIG. 23A is a top front perspective view of an in-line, multi-chamberedpre-filter according to one embodiment of the present invention.

FIG. 23B is a side view of the pre-filter of FIG. 23A showing the lid ina closed position.

FIG. 23C is a side view of the pre-filter of FIG. 23A showing the lid inan opened position.

FIG. 23D is a top plan view of the pre-filter of FIG. 23A showing thelid on one of the chambers in an opened position for access or servicingwhile the other chamber remains closed and operational.

FIG. 23E is a side cross-sectional view of the pre-filter of FIG. 23Btaken along lines 23E-23E.

FIG. 23F is a top front perspective view of one filtration chamber of apre-filter according to an embodiment of the present invention showingthe lid in an opened position to permit access to the interior forcleaning, and screen removal/cleaning.

FIG. 23G illustrates an exemplary screen for use in the pre-filter ofFIG. 23A, where the screen has desired mesh, sieve or screen openings.

FIG. 23H illustrates another exemplary screen for use in the pre-filterof FIG. 23A, where the screen has desired mesh, sieve or screenopenings.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to the drawings which depict preferred embodimentsof the present invention, but are not drawn to scale. Referring now toFIGS. 1-5, there are shown partial cross-sectional views of variousseparation tower 10 embodiments in accordance with the present inventionfor use in the treatment of solids laden water 14.

In a preferred embodiment, the separation tower 10 is orientedvertically along a longitudinal axis 13, and has an upper end 11 and alower end 12. The vessel can be any general shape, but a preferred shapewould be cylindrical or rectangular. The vessel construction is designedto be a closed system that can withstand the maximum pressure that canbe pulled by a vacuum, e.g., approx. 29.92 inches of Mercury.

A source of contaminated liquid (e.g., a solids/gas laden liquid) 15 isconveyed in the inlet conduit 24 and introduced into the separator 10via inlet 20. The inlet conduit is in fluid communication between thesource of contaminated water (e.g., a holding tank) and the separator10. Ideally, the flow rate of the mixture 15 flowing into the separator10 is regulated by, e.g., an inlet motor control valve 22. As the solidsladen liquid mixture 15 enters the separator 10, it flows downwardlyalong the first of a plurality of baffle plates (or slant plates ordeflection plates) 40. Each plate 40 has an upper end 44 and a lower end42 and is angularly disposed with respect to the longitudinal axis 13.Preferably, some of the baffle plates 40 slope downwardly toward thelower end 12 of the separator tower 10, whereby at least some of thebaffle plates 40 define a generally serpentine fluid passageway or path50 as shown by arrows 51 through which the contaminated water 15 flows.However, preferably all of the baffle plates 40 are angularly disposedas illustrated for baffle plates 40 in FIGS. 1-5. Preferably, baffleplates 40 are angularly disposed within a range of from 1 degree to 45degrees with respect to the longitudinal axis 13 of tower 10. The anglecan also preferably be between 45 and 60 degrees. The first plate 41 canalso form the base or floor of the separator and is the first plate toreceive waste stream 15 from the inlet 20. At the lower end 42 ofalternating plates 40 is located a solids discharge port 60 located inthe downward slope corner area 40 c. The plurality of plates 40 areoriented generally parallel to each other. The plates 40 are mountedwithin the separator 10 in an alternating fashion such that the spacecreated between them forms a serpentine-like flow path chamber 50 thatdirects the flow of contaminant stream 15 from the inlet 20 through thepath 50 and eventually up to the outlet 30. The separator 10 has anoutlet 30 for discharging clarified or treated water 36 through outletconduit 34 to a desired location, such as, to be recycled into thesystem, be disposed, or used as desired by the operator. Preferably, thedischarge of water through outlet 30 is regulated by a valve 32 that canbe used in connection with a means of conveyance, such as, an eductor,pump or other suitable device known in the art to draw liquid from theoutlet 30 to a desired location. As such, the lower portion of theseparator 10 containing the plurality of plates 40 forces thesolids-laden mixture to progress along the tortuous path 50 created bythe juxtapositioning of the plates 40. It is to be understood that theinvention is not limited to the exact details of construction,operation, exact materials or embodiment shown and described, as obviousmodifications and equivalents will be apparent to one skilled in theart. For example, apparatus 10 could include some, or all of thecomponents illustrated with apparatus 10, as well as the variousdeflection means may have other cross-sectional configurations thanthose illustrated.

Similar to the baffle structure depicted in connection with element 120of U.S. Pat. No. 5,741,426, the separation tower 10 of the presentinvention is an enclosed structure with an interior space 98 capable ofpermitting a vacuum to be drawn upon such space. As such, the separationtower will generally have a top wall or ceiling 10 a, a bottom wall orfloor 10 b, and one or more side walls 10 c. The separator side wall 10c can be a singular cylindrical structure (such as where the separationtower is generally cylindrical in shape). If the separation tower isrectangular in shape, then the tower would have four side walls 10 c-1,10 c-2, 10 c-3 and 10 c-4 (see FIG. 1B) generally forming therectangular shape. Within the inside of the separation tower, the towerpreferably includes a plurality of baffle plates 40 disposed in a spacedapart relationship, with at least some of the baffle plates 40 beingangularly disposed with respect to the longitudinal axis 13 of theseparation tower 10. Preferably, some of the baffle plates 40 slopedownwardly toward the lower end 74 of the separation tower 10, wherebyat least some of the baffle plates 40 define a generally serpentinefirst fluid passageway 50, as shown by arrows 51, through which thecontaminated water 15 flows. Also, the baffle plates could be disposedsubstantially perpendicular to the longitudinal axis 13 of separationtower 10. However, preferably all of the baffle plates 40 are angularlydisposed as illustrated. One of the many ways of creating the serpentineor tortuous path 50 is where the deflection members or baffle plates 40are disposed in at least two generally parallel rows, with the baffleplates of adjacent rows of baffle plates being disposed in a staggeredrelationship with each other.

With reference to FIGS. 1-3, the interior of the tower 10 can bevertically partitioned with partition bulwark 10 d. One of the twoparallel rows of baffle plates can be mounted to this partition bulwark,while the other of the two parallel rows of baffle plates can be mountedon the tower wall 10 c opposite the partition bulwark 10 d. Thepartition bulwark extends across the bottom 10 a of the tower 10interior upward toward the top of the tower 10 b, above the topmost ofthe plurality of baffle plates 40, but preferably not all the way to thetop of the tower 10 b. At the lower end 42 of each baffle plate mountedto the partition bulwark 10 d, there is found a solids discharge port60. It will be understood that each baffle plate 40 is secured in sealedrelationship on its two side edges to the inside surface of the towerwall 10 c. Although FIGS. 1, 1A, and 2-5 depict an embodiment of theseparation tower that is cylindrical in shape, other tower shapes arepossible, such as, for example, a generally rectangular shape asillustrated with FIG. 1B (with outer walls 10 c-1, 10 c-2, 10 c-3 and 10c-4).

As the contaminated water is drawn into the separator 10 through inlet20, it flows along the bottom or first plate 41 from the bottom plateupper end 41 a to the bottom plate lower end 41 b. At the lower end 41 bof the bottom plate 41, there is located the partition bulwark 10 d.Located above the contaminated water inlet 20 is a baffle plate 40attached to the separator wall 10 c at the baffle plate attachment edge40 a and extending parallel to the first plate 41. This baffle plate'slength extends across the separator but does not extend completelyacross the separator thereby leaving a gap 52 between its baffle plateouter edge 40 b and the wall opposition its point of attachment 40 a(i.e., where the plate 40 attaches to the separation tower wall 10 c,the gap will be formed between the plate outer edge 40 b and thepartition bulwark 10 d; where the plate attaches to the separationbulwark 10 d, the gap will be formed between the plate outer edge andthe separation tower wall 10 c). The contaminated water 15 moving alongthe first plate 41 is deflected upward along the bulwark 10 d until ithits the underside of the next of the alternating plates 40, this nextplate being mounted to the bulwark. The contaminated water continuesmovement upwardly until it deflects off the tower wall 10 c and upagainst the next plate, and so forth. As such, as the contaminated watercontinues to move upwardly within separation tower 10 by the operationof vacuum pump 90, undesired solid materials 16 within contaminatedwater 15 strike the underside 49 of the baffle plates 40 and are thusdirected downwardly toward the lower end 74 of separation tower 10 viabeing discharged through the solids discharge ports 60 and into thestandoff conduit 70, which, in the embodiments of FIGS. 1-3 and 5 isformed by the space between the backside of bulwark 10 d (i.e., the sideof bulwark opposite the side having the plates 40 attached thereto). Asdiscussed below, in another embodiment (see FIG. 4), the separationtower does not contain the internal bulwark 10 d and the standoffconduit 70A is formed as a separate conduit external to the separationtower 10. Preferably, baffle plates 40 are angularly disposed within arange of from 1° to 45° with respect to the longitudinal axis 13 oftower 10. Preferably, the plurality of baffle plates is located abovethe contaminated water inlet 20. The first plate 41 may serve as thebase of the separation tower 10, and would be preferably located evenwith or below the contaminated water inlet 20.

As the contaminated water 15 is drawn or urged upwardly withinseparation tower 10 by, e.g., the operation of vacuum pump 90 or othermotive means, undesired solid materials 16 within contaminated water 15strike the underside of the baffle plates 49 and are thus directeddownwardly toward the lower end 74 of separation tower 10. As the wastemixture flows downwardly along the downward slope from the plate upperend 44 to the plate lower end 42, solids 16 will fall out andpreferentially be directed into the solids discharge port 60 located inthe downward slope corner area 40 c rather than making an upward turnrequired to continue along the tortuous or serpentine path 50. Theliquid, on the other hand, will preferentially continue along the pathof least resistance up through the serpentine path 50 towards the outlet30. Each solids discharge port 60 is in fluid communication withstandoff conduit 70, 70A and is preferentially of a smaller opening sizethan that of, e.g., the outlet 30 so that the path of least resistancefor the liquid will be toward the outlet 30, and not through the solidsdischarge port 60. It will be understood to those of ordinary skill inthe art that the size and shape of the solids discharge port 60 can bevaried, for example, a rectangular slit design or a circular openingdesign are potentially used port configurations. Standoff conduit 70,70A has an upper end 72 in fluid communication with the tower interiorspace 98 and a lower end 74. As the solids 16 drop through solidsdischarge port 60, they will fall toward the standoff conduit lower end74 where they can be discharged from the separator 10 via, e.g., asolids discharge valve 80. As will be mentioned below, in a preferredembodiment, a vacuum may be applied to the interior air space 98 of theseparator 10 to assist in the solids-liquid separation, and to assist indrawing the contaminated liquid 15 into and up through the separator 10,as well as drawing off undesired gasses. If such vacuum system isemployed, then such solids discharge valve is preferably a rota-lockvalve or other valve designed to collect solids from the standoff lowerend 74 without disrupting the vacuum pressure in the system. The solids16 collected in the lower end 74 of the standoff conduit 70 can beremoved either continuously or periodically by operation of the solidsdischarge valve 80. The solids 16 that are released through solidsdischarge valve 80 can then be conveyed to another desired location bysuitable conveyance devices, such as, for example, belt conveyor, auger,cuttings box, sludge pump, etc.

Referring to FIGS. 4 and 4A there is depicted an external standoffconduit 70A that is created as a standalone pipe section. Each solidsdischarge port 60 is linked in fluid communication with externalstandoff conduit 70A via discharge port conduits 71. Although thedischarge port conduits 71 are depicted shown as horizontal conduits,they could be angularly mounted to continue the downward slope of theplate 40. As will be understood to those of ordinary skill in the art,many different standoff conduit configurations could be employed.

Preferably, the serpentine-like channel or path 50 begins proximate thecontaminated liquid inlet 20, and ends proximate the treated wateroutlet 30.

During operation of the separator, the fluid level will rise to thewater line (or liquid level) 100. The liquid level can be regulated andmonitored with a float valve/switch or other suitable device 102. In apreferred embodiment, the operation of the inlet valve 22, outlet valve32, liquid level indicator 102, and solids discharge valve 80 arecoordinated and in communication to permit smooth operation of theseparator 10.

In a preferred embodiment, a vacuum clarification system is employed.Through the use, or application of an applied vacuum, liquids having adifference of greater than 0.05 specific gravity may be effectivelyseparated. In addition, particulate solids by virtue of greater weight(or density), than the liquids in which they are suspended, may also beseparated from one or more liquid phases. The basis upon which vacuumclarification operates is that of barometric differentiation.Specifically, at sea level (0.0 ft. altitude), the atmosphere exerts aforce equal to 14.7 lbs/sq. in. This value may also be read as 760.0 mmHg (29.92 inches Hg) in a barometer. This pressure of 1 atmosphere (14.7lbs/sq. in.) also equates to an equivalent head of water of 34.0 ft. @75 degrees F.

In this preferred embodiment, a vacuum pump 90 is employed to pull avacuum on the interior air space 98 of the separator/vessel 10 viavacuum inlet conduit 92. The vacuum pump employs a discharge port 96 fordirecting discharged air/gas to a desired location of the operator(e.g., the vacuum discharge may contain gases that can be recycled foruse or must be directed to an appropriate disposal area). The vacuumpressure is regulated by vacuum regulator 94. The vacuum apparatus 90applies a vacuum in and at the top of the separation tower 10 (in airspace or vacuum chamber space 98) for drawing the contaminated waterfrom the holding tank or other source (not shown) through the waterinlet 20 and upwardly into, and through, the separation tower and forremoving undesired gaseous materials from the contaminated water.Preferably, the vacuum force is approximately 29″-29.5″ of mercury.Where a vacuum is employed, in a preferred embodiment, the operation ofthe inlet valve 22, outlet valve 32, liquid level indicator 102, solidsdischarge valve 80 and vacuum (via regulator 94) are coordinated and incommunication to permit smooth operation of the separator 10 and topermit the desired fluid level 100 in the separator 10. As a back-up orsafety kill switch, a second water level indicator switch device 104 islocated above the first water level indicator 102 and can be programmedto shut down the system in the event that the water level 100 reachesthe level of the second indicator 104. Such safety system serves, e.g.,to protect the vacuum system from receiving liquid into its pump, asdoing so could damage the vacuum equipment. The actual vacuum pump 90need not be located physically on the separator as shown, but insteadcan be located at some other location so long as the vacuum pump 90remains in vacuum fluid communication with separator 10 via vacuumconduit 91.

As seen in FIGS. 1-5, separation tower 10 generally has a circularcross-sectional configuration; however, it will be readily apparent toone of ordinary skill in the art, that separation tower 10 could haveany desired cross-sectional configuration, such as square, oval,rectangular, etc., although a circular cross-sectional configuration ispreferred. Likewise, the various fluid passageways, or conduits,described herein, disposed in fluid communication with, and betweenseparation tower 10 also preferably have a circular cross-sectionalconfiguration, but it will be readily apparent to one of ordinary skillin the art that such fluid passageways, or conduits, could have anydesired cross-sectional configuration, such as oval, square, triangular,etc. Unless hereinafter indicated, all of the components of watertreatment apparatus 10 may be made of any suitable material having therequisite strength characteristics to function as separation tower 10,as well as in the case of separation tower 10, to withstand the vacuumpressure forces that may be exerted upon separation tower 10.Accordingly, the various components of apparatus 10, unless a specificmaterial is hereinafter set forth, may be made of commercially availablemetallic materials, such as various types of steel, or various plasticmaterials, which are well known and commercially available. Since thecontaminated water is only being treated to remove sufficient amounts ofundesired solids, liquid, and/or gaseous materials to render thecontaminated water in compliance with various governmental dischargestandards, it is not necessary that any of the components of apparatus10 be constructed of stainless steel, unless the extra durability andcorrosion resistant characteristics of stainless steel are desired.

To enhance the solids-liquids separation (and separation of entrainedgasses) occurring in solid liquid separators such as separator 10, oneor more sources of vibration 110 can be applied to the walls of theseparator 10 and/or to one or more of the baffle plates 40 in anydesired location. It is preferred to provide each baffle/deflector platewith a source of vibration. Referring to FIGS. 1 and 4, in one preferredembodiment, a vibrator motor or other source of vibration 110 is mountedonto the underside of separator 10 using a suitable mount 112.

Referring to FIGS. 2 and 2A, in another preferred embodiment, a vibratormotor or other source of vibration 110 is mounted onto the side ofseparator 10 using a suitable mount 112. In this preferred embodiment,if the separator is cylindrical in shape (as shown here), thenpreferably the vibrator mount 112 is designed to evenly disperse thevibration across the outer circumferential area of the separator 10 inthe region of the baffle plates 40.

Referring to FIG. 3, in another preferred embodiment, a vibrator motoror other source of vibration 110 is mounted onto the underside ofseparator 10 using a suitable mount 112 (much like as in FIG. 1). Inthis embodiment, a vibrator connecting rod 114 is mounted within theseparator, preferably along the centerline/longitudinal axis 13. The rod114 has a top end 116 and a bottom end 118. In this embodiment, thebottom end 118 of rod 114 is fixably mounted to the first baffle plateproximate the vibrator motor 110. The rod 114 passes generally upwardthrough each adjacent baffle plate, and terminates above the last baffleplate 40. The rod 114 serves to transmit vibration from the vibrationsource 110 into each baffle/deflection plate 40. Preferably, the rod 114is fixably mounted to each baffle plate, such as by welding or othersuitable means.

Referring now to FIGS. 5 and 5A, in an alternate preferred embodiment,the rod 114 depicted in FIG. 3 can extend from the lower end 12 ofseparator/vessel 10 to the upper end 11 of separator/vessel 10. In thisembodiment, the vibration source 110 could be mounted on either theunderside or top side of separator 10 proximate to the rod lower end 118or rod top end 116.

As will be understood, one or more vibration sources 110 can positionedat any desired location on or within the separator 10. The use of thevibration source improves solid liquid separation and helps maintain aclean surface on the baffle plates 40. The vibration can be created byany available source, such as, mechanical, electrical, air-driven, orhydraulic-driven vibrator devices and/or by sonic waves, microwaves, orother source of vibration. The vibration is designed to disturb themolecular bonding of the liquids and the vibration amplification can becontrolled by means of a V.F.D. (variable frequency drive) or otherapparatus to change the rotational speed of the motor (and hence thevibration intensity). If an air or hydraulic vibrator device is used,the amplification can be controlled through pressure regulation or valvearrangements. If electric or electronic vibration such as sonic ormicrowaves are used, the amplification can be adjusted by electronicmeans. As the flow of solids laden liquid 15 enters the inlet header 20,it is directed downward across the first vibrating plate 40, 41). Thevibration applied to the bottom plate disturbs the molecular bond of theliquids and causes settling of solid particulate matter. The downwardflow path along with the vibration pushes the particulates to the loweredge 42 of the slant plate 40 where it is then directed into thestandoff conduit 70. The flow characteristics in the standoff conduitare such that the lack of flow does not keep the solid particulatesentrained, but rather permits them to fall out to the bottom of thestandoff conduit where they can be discharged for further handling,disposal or use as may be desired. The flow of the solid-liquid mixtureto be treated is directed upwardly through the tortuous path 50 causedby the baffle 40 arrangement. As the solids laden liquid moves upwardsthrough this tortuous path, separation of the solids is enhanced by thevibrational energy emitted from each plate 40, and the solids 16 areseparated and fall into the standoff conduit 70 thereby repeating theprocess until all undesirable particulate is removed. Entrained gasseswill also be released by the vibration and removed via the vacuumsource.

In another preferred embodiment of the present invention, there isdescribed an improved method of clarifying water using vibrationalenergy to enhance solid-liquid separation from a source of solids-ladenwater to be treated and/or to enhance removal of undesired gassesentrained in the waste. In this method, solids laden liquid, such aswaste water, drilling mud, etc., are introduced into a flow pathconduit. In a preferred embodiment, the flow path is serpentine-like. Inone preferred embodiment, the flow path of the liquid to be treatedwithin this conduit is oriented in a generally upward or verticaldirection—in other words, the clarified water exits the separator at apoint vertically above the separator inlet. In one embodiment, a vacuumsource is applied to assist in drawing the solids-laden liquids into andthrough the separator and to assist in the vacuum clarification of thesolid-liquid mixture to be treated. As the solid-liquid mixture movesthrough the system (either via vacuum or other motive force), a sourceof vibration is applied to the flow path. The solids falling out ofsolution are collected at a lower end of the separator for disposal orother desired handling, and the clarified liquid is collected outside ofthe outlet for further handling or disposal.

In another preferred method of the present invention, a liquid to betreated is introduced into the inlet of a separator of the types asdescribed herein in connection with FIGS. 1-5. A vacuum is applied tothe system. The liquid to be treated is then directed through a conduitconfigured into a tortuous flow path. Vibrational energy is applied tothe flow path. As solids fall out of solution, they are collected. Theclarified liquid is also collected. The solids separation system of thepresent invention can employ more than one separator, working either inparallel or in series, either alone or in conjunction with othertreatment equipment.

As mentioned above, as the solids 16 drop through solids discharge port60, they will fall toward the standoff conduit lower end 74 where theycan be discharged from the separator 10 via, e.g., a solids dischargevalve 80. Additionally, in another embodiment of the present invention,the solids discharge valve 80 is removed and the standoff lower end 74is connected to a pump (not shown). The pump serves to pull solids outof the separator conduit lower end 74 and provide a flow force for thesolids to follow. The discharge from the pump is preferably directed toa vortex removal device (not shown), such as a de-sander cone orde-silter cone (or the like) available and known to those of ordinaryskill in the art. The solids collected in the de-sander or de-silter canthen be directed to a desired place of disposal via standard disposaltechniques.

Referring now to FIG. 6, there is shown another embodiment illustratingadditional features that may be employed to benefit. For example, theseparator devices 10 described herein and in connection with FIGS. 1-6may also be outfitted with a chemical injection inlet 122 for use ininjecting desired chemicals or treatment solution streams 123 into thecontaminated feed liquid 15. The chemicals or treatment solutions 123are prepared and fed from a chemical storage receptacle (not shown)through chemical injection conduit 124 to a desired entry location inthe separator (hear, shown for example proximate the inlet valve 22, butother locations could be suitable. The chemicals or treatment solutions123 could comprise coagulants, flocculants, and other desired chemicaltreatment regimes based upon the characteristics of the solid/liquidfeed mixture 15.

Also, referring still to FIGS. 6 and 6A, the separator devices 10described herein and in connection with FIGS. 1-6 may also be outfittedwith one or more slots or upper discharge ports 125 that fluidlyconnects to a secondary standoff conduit 126. Similar to FIGS. 1-3, theinterior of the tower 10 can be vertically partitioned with thesecondary partition bulwark 127. One of the two parallel rows of baffleplates 40 can be mounted to partition bulwark 10 d, while the other ofthe two parallel rows of baffle plates 40 can be mounted on thesecondary partition bulwark 127 opposite the partition bulwark 10 d. Thesecondary partition bulwark extends across the bottom 10 a of the tower10 interior upward toward the top of the tower 10 b, above the topmostof the plurality of baffle plates 40, but preferably not all the way tothe top of the tower 10 b. On the underside of the baffle plateattachment edge 40 a of each baffle plate mounted to the secondarypartition bulwark 127 (other than the first plate 41), there is foundone or more slots or upper discharge ports 125 located in the upwardslope upper corner area 40 d. It will be understood that each baffleplate 40 is secured in sealed relationship on its two side edges to theinside surface of the tower wall 10 c. Although FIGS. 1, 1A, and 2-6depict an embodiment of the separation tower that is cylindrical inshape, other tower shapes are possible, such as, for example, agenerally rectangular shape as illustrated with FIG. 1B (with outerwalls 10 c-1, 10 c-2, 10 c-3 and 10 c-4). As such, the standoff conduit70 serves as a primary static zone while the secondary standoff conduit126 serves as a secondary static zone.

As the waste mixture flows downwardly along the downward slope from theplate upper end 44 to the plate lower end 42, solids 16 will fall outand preferentially be directed into the solids discharge port 60 ratherthan making an upward turn required to continue along the tortuous orserpentine path 50. The liquid, on the other hand, will preferentiallycontinue along the path of least resistance up through the serpentinepath 50 towards the outlet 30. Any lighter components of the wastemixture, such as gasses and oils or light colloidal or light particulateor suspended solids material, will tend to migrate up to and through theslots 125 and into the secondary standoff conduit 126. Each slot 125 isin fluid communication with the secondary standoff conduit 126 and ispreferentially of a smaller opening size than that of, e.g., the outlet30 so that the path of least resistance for the liquid will be towardthe outlet 30, and not through the solids discharge port 60. In oneembodiment, the slots 125 have a slit or opening width of about ¼ inch,and extend across the full width of the secondary standoff bulwark 127.It will be understood to those of ordinary skill in the art that thesize and shape of the slots or upper discharge ports 125 can be varied,for example, a rectangular slit design or a circular opening design arepotentially useful port configurations. Secondary standoff conduit 126has an upper end 128 and a lower end 129. As the light gasses and oils131 (or microbubbles 132 discussed below) pass through the slots 125,they migrate upward in the secondary standoff conduit 126. When thegasses break through the surface of the oil phase 133, they arepermitted to enter the evacuated airspace 98 (the upper conduit end 128being in fluid communication with the airspace 98) and be drawn outthrough the vacuum conduit 91. As the oil phase 133 reaches the topsection 128 of the secondary standoff conduit 126, the oil phase 133 canspill over a weir 137 which is in fluid connection with secondarystandoff conduit upper outlet 138 where the oil phase 133 (or otherphase present here) can be discharged through secondary standoff conduitupper discharge tubing 139 for any desired further handling, disposal orreuse.

As the colloidal or suspended solids 130 drop through upper dischargeport 125, they will fall toward the secondary standoff conduit lower end129 where they can be discharged from the separator 10 via, e.g., asecondary standoff conduit lower outlet 134 into appropriate transferpiping/conduit 135 so that the discharged contents 136 can be directedfor any desired further handling, disposal or reuse. Additionally,colloidal or suspended solids materials may become entrained in thegasses 131 or microbubbles 132 and be carried up to the oil phasesurface where the gas or microbubbles will then release such material,and such material can then coagulate and fall downward to dischargeoutlet 134.

Additionally, still referring to FIGS. 6 and 6A, the separator devices10 described herein and in connection with FIGS. 1-6 may also beoutfitted with one or more sparging devices 140 comprising an internalconduit space 140 a connected in fluid communication with a source ofsparging gas (not shown), and one or more perforations to permit thesparge gas to discharge from the internal conduit space 140 a into thesurrounding solids/liquid mixture encountered in the separation path 50.In this embodiment, the sparging gas would not be introduced in thefirst section of the path 50 along lower plate 41 because the gas wouldmigrate upward and become trapped near the contaminated liquids inlet20. Instead, the sparging device(s) are preferentially located above thesolids discharge ports 60 so that the sparge bubbles can migrate upwarduntil they reach the upper discharge slots 125. Although only one spargeunit 140 is depicted in FIG. 6 (in the upper portion of the first upwardturn of serpentine path 50), it will be understood by those having thebenefit of the disclosure herein that more than one sparge unit can beemployed, such as in the vicinity below each upwardly directed plate 40.In one embodiment, the sparge device comprises a porous tubular memberor pipe extending across the width of the path 50. In anotherembodiment, a plurality of individual sparge devices are mountedproximate each other. In one embodiment, the sparge gas exits the spargedevice as microbubbles. The microbubbles or microfine bubbles can assistin washing the solids. In one embodiment, the sparge gas is carbondioxide. In another embodiment, the sparge gas is selected based on itsability to assist in removing or scrubbing oil from the solids phase ofthe solid liquid feed mixture 15. In one embodiment, carbon dioxide isused as the sparge gas to help wash the oil off of the solids phase. Inanother embodiment, sparging devices are located at every upward turn inthe serpentine path 50. The sparge gas or air can vary in chemicalmakeup and temperature. Sparge gas temperature may be adjusted toinfluence the viscosity and settling rate of the fluids being treated.The actual bubble size achieved within the flow path 50 may depend on anumber of factors, including, the changing conditions of the solution 15being treated, the temperature, viscosity, solids loading, etc.

The introduction of micro-bubbles will temporally reduce the viscosityof the fluid 15 thereby allowing more particles 16 to migrate downwardlyto the primary static zone for removal and disposal. The very smallparticles not removed will attach themselves to a gas bubble and becomebuoyant thereby allowing the removal upwardly to the secondary staticzone (similar to Dissolved Air floatation (DAF) technology) rather thancontinuing along the path 50 to the exit 30. A preferred sparge gas foroil separation is carbon dioxide gas as it has a natural affinity foroil and greatly aids in the separation and reclaiming of oils. The oilswill collect in the secondary static zone where it will build up andflow over the overflow weir 137 into a tank (not shown) for removal andreuse or disposal. The colloids or other small suspended solids willmove into the secondary static zone where they will lose the attachedgas bubble to the vacuum and settle over time to the bottom of thesecondary zone to be removed through port 134 located at the lowerextremity of the secondary static zone. The separator device of thepresent disclosure can permit 3-phase separation of liquids that arecontaminated by solids and oils.

In yet another embodiment of the present disclosure, an array ofspaced-apart, electrodes 142 can be introduced into the flow path 50 toserve as a source for introducing an electrical current into the fluids15 to permit electrocoagulation to take place. In one embodiment, theelectrodes are rods that extend across the flow path 50 from side toside in a matrix that itself creates a tortuous path that createsimpingement of the solids causing the solids to strike the electrodesand slow down. The electrodes are electrically insulated at the point ofattachment to the walls of the separator (e.g., with suitable insulatinggrommet or the like that can also serve to create a seal around suchpoint of attachment), and are also spaced apart so that the electrodesdo not touch each other. In another embodiment, the electrodes protrudeinto the flow path 50 in a staggered length fashion. Sufficient spacingexists between the electrodes 142 and the plates 40, 41 so as to permitsolids to pass therebetween. A current is induced into the electrodes,and the polarity of the electrodes is alternated between positive (+)and negative (−) polarity. Process control equipment (not shown)automatically controls the polarity of the electrodes (and theamperage/voltage). An appropriate current is induced (for example, a lowamperage current such as about 15 amps of current but other suitablecurrents can be employed.) into the electrodes.

The array of rods 142 to be used as positive and negative electrodeswill be inserted between the first and second plates 41, 49 to allowmaximum contact of the fluid 15 being directed through the system. Theelectrodes 142 can comprise any material that will conduct current flow,such as iron, aluminum, stainless steel, carbon fiber, etc. A preferredmaterial for the electrodes 142 is carbon rods. Carbon rods have provento be more resistant to decay from the electrical activity and moreresistant to scale buildup. The addition of electro-coagulation willcarry many benefits including but not limited to removal of certaindissolved solids such as heavy metals and destruction of undesiredbacterial contamination.

Referring now to FIG. 7, the separator devices 10 described herein andin connection with FIGS. 1-6 may also be outfitted with a vacuumassisted accumulator 150 for collecting oil 133, 133 a from theseparator 10. For convenience, the same numbering is used in connectionwith FIG. 6 in connection with the separator device 10. In theseembodiments, the accumulator 150 is in fluid, vacuum connection with theevacuated airspace 98 of the separator 10. The accumulator has a sealedaccumulator housing 156 defined by outer sidewalls, an accumulatorbottom 152 and accumulator top 154 all defining an internal accumulatorchamber 157 where oil 133 a may be collected within the evacuatedairspace of the internal chamber 157. The accumulator has an oil inlet158 in fluid communication with accumulator evacuated interior chamber157 and an accumulator oil inlet conduit 160 in fluid communication withthe accumulator oil inlet 158 and the secondary standoff conduit upperoutlet 138 to permit oil that has risen in the secondary standoffconduit 126 to flow to the accumulator 150.

The accumulator 150 is vacuum assisted by, e.g., utilizing vacuumequalizer conduit 162 having accumulator vacuum equalizer conduit inlet164 in fluid communication with evacuated airspace 98 and accumulatorvacuum equalizer conduit outlet 166 in fluid communication withevacuated accumulator air space internal chamber 157. The accumulator150 interior chamber 157 is preferably equipped with an upper liquidlevel control device/sensor (e.g., float switch, electronic sensor,sonic sensor, and the like) 168 for detecting the oil surface level 133a of oil collected in the accumulator 150. A lower liquid level controldevice/sensor (float switch, electronic sensor, sonic sensor, and thelike) 170 for detecting when oil surface 133 a collected in accumulator150 has drained to a lower level. The collected oil may be dischargedfrom the accumulator 150 via oil outlet 171 and through oil outletconduit 172 for directing accumulated oil to desired storage or end uselocation (not shown). An oil outlet control valve 174 with a one waycheck valve 176 on the exit side of oil outlet control valve 174regulates the flow of oil out of the accumulator 150. In operation, whenthe oil spills over the weir 137 (FIG. 6) or through the other weirdesigns described herein (e.g., FIGS. 8A-8E), and drains down into thevacuum assisted accumulator tank 150, the oil will begin to fill thetank and when it reaches the upper sensor 168, it will activate thedischarge pump 174 to draw the oil level 133 a down to the lower sensor170 which will in turn signal the pump 174 to stop. The pump 174 can bea centrifugal, rotary vane, gear pump, etc. A positive check valve 176is installed on the discharge port of the pump 174 to prevent vacuumloss during pump start up and shut down. The oil is pumped throughconduit 172 to a storage tank or other desired final destination.

Referring now to FIG. 7A there is depicted an alternate embodiment ofthe accumulator 150 a. Accumulator 150 a is similar to accumulator 150(FIG. 7) except that it employs a central partition/weir 178 extendingfrom the floor/bottom 152 of accumulator 150 a to a desired heightwithin the accumulator interior space. The partition 178 creates a lowerright chamber 180 and lower left chamber 182 in the accumulator 150 a.As the oil 133 from accumulator oil inlet conduit 160 enters theaccumulator 150 a, it fills the lower right chamber 180. The cleaner oilwill rise to the top and spill over the top of the partition/weir 178into the accumulator lower left chamber 182. Any contaminants in the oilin the right side chamber 180 will sink to the bottom and can be removedthrough the right chamber discharge outlet 181 through discharge conduit184 and through a control valve 186 and one-way check valve 188 anddirected to a desired location via conduit 184. The cleaner oil 133collected in the left side lower chamber 182 may be discharged via oiloutlet control valve 174 with a one way check valve 176 on the exit sideof oil outlet control valve 174 to thereby regulate the flow of oil outof the accumulator 150 a. The oil 133 may be directed to a desiredlocation via the conduit 172. Suitable liquid level sensors 168, 170 and190 may be employed to interface with the flow control valves 174, 186.The accumulator 150 a may also be outfitted with one or more auxiliaryports 192 for pumping down the system or bleeding atmosphere into thesystem during shutdown or maintenance. The extra ports allow moreversatility for the accumulator.

Referring also to FIG. 7 and FIGS. 8A-8E, the separator devices 10described herein and in connection with FIGS. 1-6 may also be outfittedwith a variety of adjustable weir configurations 200, 208, 212 used inconnection with the discharge of oil 133 from the secondary standoffconduit 126 (see location call-out 8A-8E of FIG. 7). For example,although FIG. 6 depicts an internal fixed weir 137 (which could also beconfigured to be a height adjustable weir), alternate weirconfigurations, that are preferably located external to the secondarystandoff conduit 126 to facilitate access, can be employed to provideheight adjustment of the weir to enhance the separation of oil fromwater and solids. Like with weir 137, adjustable weirs 200, 208 and 212are coupled with the secondary standoff conduit upper outlet 138. Thefunctions of the weirs are the same for each embodiment—to assist inbetter separating the oil from the water and solids mixture.

One example height adjustable weir is depicted in FIG. 8A. In thisembodiment, there is employed a rotatably adjustable weir 200 comprisinga swivel joint 202 installed inline in the accumulator oil inlet conduit160 a. The swivel joint 202 may be adjusted to a desired angle 204. Theswivel joint 202 may be manually adjusted or automatically adjustablevia process control of a swivel motor (not shown). As the angle 204 isincreased between 0 degrees (static position) and up to 90 degrees(adjusted position), the effective weir height 206 a is increased bycausing the conduit 160 a (preferably a flexible conduit) to moveupwards thereby increasing the effective height 206 a of the weir 200.The oil 133 flows through the weir 200 (via conduit 160 a) to a desiredlocation, e.g., the accumulator 150 as depicted in FIG. 7.

FIG. 8B discloses a tubing height adjustable weir 208 embodiment. Inthis embodiment, the oil 133 discharges from the secondary standoffconduit 126 into flexible conduit 160 b. The effective weir height 206 bis created by raising and lowering the flexible conduit, such as, forexample, by raising or lowering a conduit guide 210 that cradles theconduit 160 b, or otherwise serves as a guide to hang conduit from ordrape the conduit over. As the conduit guide 210 moves upward, theeffective weir height 206 b increases. The conduit guide 210 can befashioned from any type of interface that will permit sliding interfacewith the conduit 160 b. For example, the conduit guide 210 couldcomprise a moveable bar, a moveable roller, a moveable sleeve, a guidewheel, or the like that can interface with the conduit 160 b and urgethe conduit upwards or downwards, preferably without creating anykinking in the conduit. The upward and downward movement of the conduitguide 210 may be manually adjusted or automatically adjustable viaprocess control of a motorized mechanism (not shown).

Alternately, the conduit 160 b could simply be manually raised orlowered to a desired effective height 206 b and secured in place withone or more suitable fasteners (preferably where the fasteners arecapable of quick fastening and unfastening). Additionally, one or morefixed position conduit guides could be arranged to permit a fixedselection of height adjustment by placing (or otherwise attaching) theconduit 160 b over (or to) the desired conduit guide to achieve thedesired effective height 206 b.

Referring now to FIGS. 8C-8E there is shown a gate height adjustableweir 212. In this embodiment, the basic structure comprises a moveablegate 214 that is capable of moving upward or downward in a slot 216defined by opposed slot walls 218 a, 218 b (or other suitable structureor tracks. The gate 214 is sized and mounted proximate the dischargeopening 138 of the secondary standoff conduit 126. In this embodiment,the discharge opening is shown having an upper boundary 138 a and alower boundary 138 b. The effective weir height 206 c is therebyadjusted by moving the gate 214 up or down within the slot 216. FIGS. 8Cand 8E shown the gate in a lower position; FIG. 8D shows the gate in araised position. Suitable stops (not shown) could be employed, ifnecessary, to stop the upward travel of the gate 214 at a desiredlocation. The height of the gate 214 would be sized to permit thedesired effective weir height 206 c to be obtained. In this embodiment,the weir 212 is attached in sealed relationship with the separator 10 topermit the ambient evacuated internal airspace 98 of the separator 10 tobe in fluid communication with the internal airspace 220 of the weir212. The weir 212 further comprises an outer housing 222 maintained insealed relation to the separator 10. As oil 133 flows up the secondarystandoff conduit 126, it then proceeds through the secondary standoffconduit upper outlet 138 and over the top of the height adjusted gate214 and into the internal section 220 of the housing 222. Dischargeconduit 160 c is attached to the bottom of the housing 222 to permit theexit of oil 133 through the conduit 160 c to a desired location, e.g.,the accumulator 150 as depicted in FIG. 7. In this embodiment, the gateheight may be adjusted manually or by motorized, process controlmechanisms known in the art. For example, as depicted, stanchions orposts 224 (that pass through housing 222 in sealed fashion) could bemanually raised or lowered to place the gate 214 in position for thedesired weir height 206 c, or could be connected to a motor toautomatically raise or lower the gate. It will be apparent to those ofordinary skill in the art having the benefit of this disclosure thatcountless mechanisms can be employed to achieve gate movement, eithermanually or automatically. For example, mechanical geared mechanismscould be employed to move the gate up or down. Hydraulics could also beemployed, such as, for example, by integrating a hydraulic lift system(not shown) in the slot 216 with a hydraulically actuated piston beingmounted in the slot to the inner housing and underside edge of the gate214 to permit the piston to move the gate 214 up and down within theslot 216. A sealed hatch (not shown) could be installed on the housing222 to permit ready access to the interior of the gate adjustable weir212 to permit, e.g., manual adjustment of the weir height ormaintenance/cleaning.

Although embodiments have been shown illustrating height adjustableweirs, those of ordinary skill in the art having the benefit of thisdisclosure could create other alternative embodiments that are withinthe scope of this invention.

Referring now to FIGS. 9-16 in conjunction with the above teachings,there is shown a treatment system 300 employing another embodiment of aseparation tower or vessel 310 within a housing or frame 302. In thisembodiment, the housing is depicted as a framework 302 suitable forhaving the separation tower or vessel 310 mounted therein. In thisparticular embodiment, the framework comprises horizontally disposedbase members 302 a, vertically disposed side members 302 b, andhorizontally disposed top members 302 c creating a substantiallyrectangular framework. In this embodiment, the vessel 310 is suspendedfrom the frame top members 302 c by suitable hangers 304. In oneembodiment, the hangers 304 comprise an upper mount 304 a fixablyattached to the frame 302, a lower mount 304 b fixably attached to thevessel 310 near its top, and a connector 302 c connected therebetween.In one embodiment, the connector comprises a fiber-reinforced rubbermaterial (such as a fan-belt type material) capable of holding thedesired weight of the suspended vessel 310, while also providingvibration dampening between the vessel 310 and the frame 302. In anotherembodiment, the connector is a steel cable, rope, synthetic webbingmaterial, and the like to suspend the vessel 310 and serve as avibration dampener between the vessel 310 and the frame 302. It will beunderstood by those having the benefit of this disclosure that manysuitable ways exist to mount the vessel into a housing, for example, thevessel 310 may employ external framework (not shown) that can be mountedto a housing in a manner suitable for providing vibration dampening orvibration isolation. Also, the vibration isolation feet that are used onvibratory shale shakers and the like could be employed. It will also beunderstood that the system 300 could be designed to any desired scale,and could be permanently installed on-site, or could be mounted on aportable bed or skid, or trailer, or onto another mobile vessel, such asa barge, boat or ship.

Referring now to the separation tower or vessel 310 itself, it will beunderstood that it may employ similar operational features as thosedescribed above in connection with other embodiments of separation toweror vessel 10 herein, for example, the use of the serpentine path, thestandoff conduits, etc. In this embodiment, the separation tower orvessel 310 generally has an upper end, 311 and a lower end 312, and alsogenerally comprises two vertical chambers or stand-off conduits (firstchamber) 426 and (second chamber) 370 connected by a serpentinepassageway 350 (which may be similar to passageway 50 described above,but not necessarily employing as many path turns as depicted in, e.g.,FIG. 6) formed by a desired number of baffle or slant plates 340. Itwill be understood that each baffle plate 340 is secured in sealedrelationship on its two side edges to the inside surface opposed sidewalls of the serpentine passage 350. Here, the serpentine or tortuouspassageway 350 is depicted as comprising only one baffle plate 340having upper surface 348 and underside surface 349 installed so as todivide the serpentine passageway 350 into a first downwardly-directedsegment 350 a and a second upwardly-directed segment 350 b. An upperconduit or flow channel (tray) 333 connects the first and secondchambers 426, 370.

The vessel 310 has an inlet conduit 324 for receiving the liquid/solidslurry mixture 315 that is to be treated through inlet 320. For example,this slurry could be a water-based drilling fluid that has becomecontaminated with undesirable low gravity solids (LGS). Heavy solids 430or discharge contents 436 (e.g., the desired components of a drillingfluid) are discharged from the bottom 429 of the first chamber 426 (anddirected to a desired location, e.g., to be used in rebuilding orrecycling of drilling fluid). Desired heavy solids or dischargedcontents 316 are also discharged from the bottom 374 of the secondchamber 370. The liquid phase 336 containing the undesired LGS isdischarged from the vessel 310 via outlet conduit 334 through controlvalve 332. The vessel 310 also employs sparging devices 440 fordispersing air or other gas throughout the liquid mixture 315.Additionally, one or more sources of vibration, such as a vibrator motor410, is mounted to the vessel 310. Here there is shown a vibrator motor410 being mounted on an external wall of the serpentine channel 350. Thevibration assists in urging the heavier solids to settle and, e.g., dropout of the lower portion of the vessel as a slurry.

In this embodiment, the vertical chambers 426 and 370 are shown beingsubstantially identical in structural configuration. However, as will beappreciated, the vertical chambers need not be identical. First verticalchamber 426 is shown as a generally vertically disposed rectangularstructure (it could also be other shapes, such as, cylindrical) having aan upper end 428, a lower end 429, outer walls 426 a, 426 b, 426 c, 426d, underside 426 e, and top 426 f. The top 426 f comprises an openinginto the interior space 398 a of the chamber 426. A top door or hatch426 g is attached (here by hinge 426 h) to cover the top 426 f (whenhatch is closed) in sealed fashion (employing air tight gasket 426 i)and held in place using a suitable fastener(s). The underside 426 e ispreferably tapered or sloped in funnel-like fashion, with downwardly andinwardly sloping walls that lead to solids discharge port or outlet 434where separated solids 430 can be directed away via conduit 435.

Similarly, second vertical chamber 370 is shown as a generallyvertically disposed rectangular structure (it could also be othershapes, such as, cylindrical) having a an upper end 372, a lower end374, outer walls 370 a, 370 b, 370 c, 370 d, underside 370 e, and top370 f. The top 370 f comprises an opening into the interior space 398 bof the chamber 370. A top door or hatch 370 g is attached (here by hinge370 h) to cover the top 370 f (when hatch is closed) in sealed fashion(employing air tight gasket 370 i) and held in place using a suitablefastener(s). The underside 370 e is preferably tapered or sloped infunnel-like fashion, with downwardly and inwardly sloping walls thatlead to solids discharge port or outlet 380 where separated solids 316can be directed away via conduit 381.

At the desired liquid level 400 within the vessel 310, the first chamber426 is interconnected, in fluid communication, with the second chamber370 via upper fluid conduit 333. The upper fluid conduit 333 has a firstend opening 333 a at one end that opens into chamber 371 and a secondend opening 333 b at its other end that opens into chamber 426 to permitthe fluid 336 from the second chamber 370 to move through the upperconduit 333 to the first chamber 426, and then out of the vessel vialiquid outlet conduit 334 (via its opening 334 a), through control valve332 to a desired location. Each chamber 426, 370 has a desired airheadspace 398 a, 398 b above the operative liquid level 400. Duringoperation of the separator 310, the fluid level will rise to the waterline (or liquid level) 400. The liquid level can be regulated andmonitored with a float valve/switch or other suitable device 402.Preferably during operation, the liquid level is maintained at theapproximate mid-height of upper conduit 333 so that the lightercolloidal or LGS that are floating or otherwise being urged upwardly inthe second chamber can then migrate across the conduit 333 to bedischarged through discharge conduit 334.

In the embodiment of FIGS. 9-16, the first vertical chamber 426 alsocomprises one or more sparging devices 440 disposed proximate the lowerend 429 of the first chamber 426 to disperse sparge air or gas upwardlywithin the fluid column contained therein. The sparge gas assists inurging, or otherwise floating, the colloidal materials or LGS to the topof the vessel for discharge. The first chamber 426 also preferablyfurther comprises one or more substantially vertically-oriented internalbaffle plates 405 disposed between the lower end 429 of the firstchamber 426 and the area just beneath the level of the upper conduit 333and outlet conduit 334. Each baffle plate has an upper end 405 a and alower end 405 b, and opposed vertical edges that are fixably attached toopposed interior walls within the first vertical chamber 426, the platesbeing spaced apart in substantially parallel fashion to createsubstantially vertical fluid channel paths 407 therebetween. The channelpaths create preferred paths for urging the colloidal or LGS materialsupwards. In a preferred embodiment, two baffle plates 405 are employedto create three fluid channel paths 407. The fluid channel paths shouldbe narrow enough so that the introduction of sparge gas at the base ofthe channel will cause bubble flow within the chamber to push anycolloidal or LGS materials to the top of the channel. When baffle plates405 are employed, it is preferable to position a sparging device 440 atthe lower end of each fluid channel path 407. In another embodiment, nobaffle plates 405 are employed and the interior of the first verticalchamber serves as the substantially vertical fluid channel path 407. Byintroduction of microbubbles into the liquid stream, the bubbles createan alteration (a lowering) of the liquid viscosity where the bubbles arepresent, the bubbles also provide lift, both of which assist in movingthe LGS and colloidal materials to the top of the water surface andultimately out of the system via outlet 334. The sparge gas helps todrive any colloidal materials to the top of chamber 426 where they canexit out discharge conduit 334, or to urge any residual colloidalmaterials present in chamber 370 up to the surface (water line 100)where they can then migrate across the tray 333 into chamber 426 and outof the separator via outlet 334.

Likewise, the second vertical chamber 370 also comprises one or moresparging devices 440 disposed proximate the lower end 374 of the secondchamber 370 to disperse sparge air or gas upwardly within the fluidcolumn contained therein. The sparge gas assists in urging, or otherwisefloating, the colloidal materials or LGS to the top of the vessel fordischarge. The second chamber 370 also preferably further comprises oneor more substantially vertically-oriented internal baffle plates 406disposed between the lower end 374 of the second chamber 370 and thearea just beneath the level of the upper conduit 333 and upper conduitopening 333 a. Each baffle plate has an upper end 406 a and a lower end406 b, and opposed vertical edges that are fixably attached to opposedinterior walls within the second vertical chamber 370, the plates beingspaced apart in substantially parallel fashion to create substantiallyvertical fluid channel paths 408 therebetween. The channel paths createpreferred paths for urging the colloidal or LGS materials upwards. In apreferred embodiment, two baffle plates 406 are employed to create threefluid channel paths 408. When baffle plates 406 are employed, it ispreferable to position a sparging device 440 at the lower end of eachfluid channel path 408. In another embodiment, no baffle plates 406 areemployed and the interior of the second vertical chamber serves as thesubstantially vertical fluid channel path 408.

Still referring to FIGS. 9-16, as the fluid mixture 315 to be treatedenters the inlet conduit 324, it proceeds generally upwards towards theentrance junction 350 c of the serpentine passageway 350 and the firstvertical chamber 426 (see arrows indicating flow path). In this entrancejunction 350 c is also located a first serpentine path sparger 440(having internal conduit space 440 a). Also in this junction 350 a is anupper discharge slot 425 (much like slot 125 described in earlierembodiments) that permits flow of the liquid 315 into the first verticalchamber 426. At this first juncture 350 c, the sparger 440 will assistin urging the light colloidal and LGS materials upwardly into the firstchamber 426 (where the sparging therein will also tend to drive thesecolloidal and LGS materials further upward and out the upper liquidexit. Additionally, the fluid mixture 315 will also enter the serpentinepath 350 and proceed downwardly into the first segment 350 a of theserpentine path. At this first junction 350 c, the action of the sparger440 bubbles serves to direct or float the lighter solids, colloidal andother low gravity solids upward through the upper discharge slot 425 andinto the first vertical chamber 426. The heavier solids 316 in the fluidmixture 315 (e.g., the desired drilling fluid mixture) will gravitatedownwardly along the downward slope of the first segment 350 a of theserpentine path 350 until reaching the second junction 350 d of theserpentine path 350. In this second junction 350 d, the solids willpreferentially exit out of discharge port 360 (similar to discharge port60 above) that leads into the lower end 374 of the second verticalchamber 370. As discussed above, spargers 440 can be preferably placedwithin the serpentine unit at every upturn of the pathway to prevent anysolids materials from back flowing down from above.

The undesirable colloidal or LGS materials, if still present in thesecond vertical chamber, will be driven/floated upwardly by sparge gasuntil they reach the entrance 333 a of the upper conduit 333 and thenwill migrate across the upper conduit 333 until reaching the top of thefirst chamber 426 where the LGS and colloidals will continue to be urgedupward in the liquid 336 and out the outlet port 334.

Referring now to FIGS. 15A and 15B, there is illustrated one of thesparging devices 440 used in the separation vessel 310. In thisparticular embodiment, the sparging device 440 is a length of tubularmaterial 440 b spanning across the width of the chamber 370. Forexample, the sparging devices (e.g., tubes) 440 in this embodiment areinstalled between opposed walls, e.g., between wall 426 a and wall 426 cof chamber 426, or between wall 370 a and 370 c of chamber 370. Thetubes 440 b in this embodiment are mounted via suitable through-wallmounting fittings, where one end of the tube 440 c is capped in sealedfashion, while the other end 440 d contains a coupling for receiving asource of sparge air or gas delivered via, e.g., sparge gas tubes (notshown). In this embodiment, the sparge tube 440 b is perforated with adesired degree of perforations or porosity/permeability to create adesired array of bubbles or microbubbles (as noted above in connectionwith earlier embodiments). Spargers are known in the art, such as thoseoffered by Mott Corporation (Farmington, Conn.) via their website,http://www.mottcorp.com/products/sparger/sparger.cfm. In one embodiment,the sparge tubes are tubes that are perforated with a plurality ofholes. Preferably the spargers are constructed of porous metal material(such as, e.g., a wide range of materials including 316L stainless steel(standard), Nickel 200, Monel® 400, Inconel® 600, Hastelloy®C-22/C-276/X and Alloy 20) to achieve high-efficiency gas/liquidcontacting. In one embodiment, the spargers 440 are single element tankspargers mounted between opposed sides of the vessel's 310 walls asnoted above. Additionally, in another embodiment, the spargers 440 aresingle element side mounted or flange side mounted sparger tubes thatattach only through one wall, and extend inwardly from a desiredposition on the wall to a desired length. Other sparging tubearrangements can be employed, such as the use of a ring spargerconfiguration, a disk sparger, or a manifolded (cross) spargerconfiguration and the like.

As will be understood from the earlier embodiments, the spargers 440 areplaced in areas of the vessel 310 (i.e., at the entrance 350 c to thefirst segment 350 a of serpentine path 350, and at each turn of theserpentine path, e.g., the entrance area 350 d to the second segment 350b of the serpentine path 350. The spargers in the serpentine path aresized and located such that they do not physically block the path of thesolids flowing through the serpentine channel. Additionally, spargers440 are located near the lower ends 429 and 374 of chambers 426 and 370,respectively to introduce the desired bubbles or microbubbles upwardlyin those chambers. For example, where the chambers 426, 370 areoutfitted with one or more baffle plates 405, 406, respectively tocreate the respective substantially vertical flow path channels 407 and408, then it is preferred to mount spargers 440 proximate the loweropenings of such channels 407, 408 to permit the desired volume and typeof bubbles to move upwardly thought such channels 407, 408. Asillustrated in FIGS. 15 and 16, one sparger 440 is located beneath theopening of each vertical flow path channel 407, 408 in a manner thatpreferably provides uniform distribution of bubbles upwardly throughsuch channels. In a preferred embodiment, spargers are used in theserpentine pathway 350 and in the base of both vertical chambers 426,370.

In a preferred embodiment, a vacuum clarification system is employed(much like as described above in connection with earlier embodiments) inconnection with the operation of the vessel 310. In one embodiment, anoptional vacuum pump (such as like illustrated as 90 in FIG. 6) may beemployed to pull a vacuum on the interior air space 398 of theseparator/vessel 310 via a vacuum inlet conduit (not shown). Much likedescribed above, the vacuum pump employs a discharge port (not shown)for directing discharged air/gas to a desired location (e.g., the vacuumdischarge may contain gases that can be recycled for use or must bedirected to an appropriate disposal area). The vacuum pressure isregulated by a vacuum regulator (not shown). The vacuum apparatusapplies a vacuum in and at the top of the separation tower 310 (in airspace or vacuum chamber space 398) for drawing the contaminated liquids315 from the holding tank or other source (not shown) through the liquidinlet 324 and upwardly into, and through, the separation tower and forremoving undesired gaseous materials from the contaminated water.Preferably, the vacuum force is approximately 29″-29.5″ of mercury.

Where a vacuum is employed, in a preferred embodiment, the operation ofa valve (not shown) regulating the inlet 324, outlet valve 332, liquidlevel indicator 402, solids discharge valve (not shown) and vacuum (viaregulator, not shown) are coordinated and in communication to permitsmooth operation of the separator 310 and to permit the desired fluidlevel 400 in the separator 310. As a back-up or safety kill switch, asecond water level indicator switch device 404 is located above thefirst water level indicator 402 and can be programmed to shut down thesystem in the event that the water level 400 reaches the level of thesecond indicator 404. Such safety system serves, e.g., to protect thevacuum system from receiving liquid into its pump, as doing so coulddamage the vacuum equipment. The actual vacuum pump (not shown) need notbe located physically on the separator, but instead can be located atsome other location so long as the vacuum pump remains in vacuum fluidcommunication with separator 310 via a vacuum conduit (not shown).

The vessel 310 depicted in FIGS. 9-16 could also be outfitted with oneor more electrocoagulation electrodes (not shown) located within theflow path such as described above in connection with earlier embodimentsto serve as a source for introducing an electrical current into thefluids 315 (where appropriate) to permit electrocoagulation to takeplace. The electrodes could be located within the serpentine path 350 orin the vertical chambers 426, 370. As also may be desired, the fluids315 could go through an electrocoagulation unit prior to entering theseparation vessel 310. Typically, electrocoagulation would not beemployed with fluids that contained oil or other potentially flammablematerials. Thus, electrocoagulation would typically not be used for anoil base drilling fluid. Further, oil can coat the electrocoagulationelectrodes thereby diminishing their effectiveness. However,electrocoagulation could be used on, e.g., water base drilling fluids,fracturing water separation, produced water, and other water-basedfluids.

The adjustable weir embodiments described above (e.g., in connectionwith FIG. 7 and FIGS. 8A-8E), used in connection with the discharge ofoil 133 from the secondary standoff conduit 126 (see location call-out8A-8E of FIG. 7) could also be employed in conjunction with the liquidoutlet conduit 334, namely, the liquid conduit outlet could also beheight adjustable to serve as an adjustable weir.

As will be understood, during operation of the vessel 310, solids flowscan be taken off of both side exits 380 and 435. Thus, if the system isbeing used to treat a drilling fluid, then the discharge 316, 430, 436from the lower ends of the vertical upper chambers 426 and 370 can beused to reconstitute a drilling mud to the desired mud weight.

Referring now to FIGS. 17-21 there is shown an exemplary tank 500 thatcould be used to receive fluids 315 prior to sending the fluids to theseparation vessel 310. In this particular embodiment, the tank 500 isdivided into two chambers, 502 and 504 (via divider plate 501, eachchamber having lids 506, 508 that can be opened and closed. Each chambercan also be outfitted with inlet ports 510, 512 (for receiving thedesired input fluid) and outlet ports 514, 516 for directing thecontained fluids to a next desired location, e.g., the inlet 324 ofseparator vessel 310. The tank 500 can also be outfitted with one ormore drains in its base to permit emptying of the contents to a desirelocation. The tank can rest elevated above the ground on suitable basemembers or feet 520. Each chamber may employ one or more stirring oragitation units 522 to prevent settling.

In one embodiment, the tank 500 can be outfitted with a heating unit orheat exchanger to heat the contents of the inlet chamber 504 receivingthe fluid 315 to be treated. The fluid is then heated and agitated, andthe heated fluid is then pumped to the inlet 324 of the separationvessel 310. The separation vessel 310 can be outfitted with one or morethermometers 530 to monitor the temperature of the fluid within thesystem. The heating unit in the tank will also have its own thermometerto regulate temperature. The cleaned fluid (i.e., the fluids that havehad the LGS removed) can be directed from the discharges (380, 435) invessel 310 back to the second tank chamber 502 for storage and testingof the LGS levels. The heating unit used to heat the contents of chamber504 could be any suitable heating unit, such as a boiler, e.g., 2-pass,3-pass, 4-pass, or multi-pass boilers, such as those available by, e.g.,CleverBrooks, Volcano, Miura, Sasebo, and others known in the art. Inone embodiment, the boiler is portable and able to be co-located on thesame transport skid or trailer as the separation vessel 310 to providefor a portable unit.

The heating of the input solution 315 can either be accomplished viabatch heating, such as in tank 500, or via an in-line heating system(not shown).

In some circumstances, the input fluid 315 may already be heated. Wherethe fluids to be treated are water base, the preferred temperature rangefor the input solution 315 is between ambient and 211° F. (i.e., lessthan the boiling point of water), but heating may be at highertemperatures, particularly with oil base muds. With water base drillingmuds, it is preferred not to heat the mud above the boiling point ofwater so as to avoid dewatering the drilling fluid (i.e., to maintainthe drilling fluid in its useable form so that it can be recycled forreuse. As such, the systems of the present disclosure can utilize aheating unit to heat the input fluids prior to entry into the separationtower 10, 301.

Referring now to FIG. 22, there is illustrated one exemplary flowdiagram of a system 600 for treating fluids. As will be understood, thefluids to be treated can originate from many sources, such as, forexample, and without limitation, storage tanks 602, 604, 606 or fromrail tank cars 608 or tank trucks 610, barges and other marine vessels(not shown) or the like. In some circumstances, such as cleanup of anoil spill into fresh or salt water, the contaminated water can be pumpeddirectly to the separation vessel 310 (or pretreatment screen 702 and orheater 800. In each case, the input fluids 315 from such tanks, tankcars, tank trucks, etc. are pumped (via pumps 612) through conduitstoward the separation vessel 310. If desired, the fluid 315 can first berun through a screening device 700 (for example, the screening device702 described below) or other suitable screening device to remove largedebris, chunks of rubber, etc. that might be present in the fluid 315.The filtered fluid 315 can then enter into a heating unit 800 (such asdescribed above as part of tank 500) or heat exchanger to heat the fluidto a higher temperature. The heated fluid 315 is then directed viaconduit to the entrance 324 of the separation vessel 310. The liquiddischarge 336 from vessel 310 could be directed to any desired location,including to tanks 602, 604, 606, or to tank 607. In another embodiment,the system 900 comprises a mobile unit, e.g., on portable skid,containing a screening device 700, 702, a heating unit 800 and aseparation vessel 310.

Referring now to FIGS. 23A-23H, there is shown an exemplary fluid solidsscreening device 702 for screening input fluid 315 for large debrisprior to permitting the fluid 315 to enter into the heater 800 orseparation vessel 310. This screening device 702 comprises twoseparation chambers 710A, 710B. Each separation chamber furthercomprises a fluids inlet 712A, 712B; a first interior solids collectionarea 714A, 714B, which might include a deeper sump area 716A, 716B. Thechambers also each have a second interior chamber area 715A, 715B. Thechambers 710, 710A each have a removable screen 718A, 718B disposedsubstantially vertically within the chamber, between the first andsecond interior areas 714A/714B and 715A/715B. The screen is held inplace via, e.g., opposed slots 720A, 720B formed from, e.g., angle iron.Each chamber has a removable door or hatch 722A, 722B on top. The doorscan be hinged to permit ease of opening, and can also be outfitted withhydraulic action arms to permit ease of lifting and opening the hatch.When the hatch is closed, the input fluids 315 enter the screen devicechambers 710A, 710B. Large debris (D) is blocked by the screens 718A,718B and falls into the sump area 716A, 716B. The fluid then flowsthrough the screen (which is perforated with a size suitable forscreening out the desire size debris), into the second interior chamber715A, 715B, and then out of outlet 724A, 724B into conduit 726A, 726Bwhich is then directed to the next phase of the system.

In this embodiment, the screening device is immediately upstream of theheat exchanger; thus, the discharge from screen device 702 is thendirected to the inlet of heater 800. In a preferred operation of thesolids screen device, the input fluids 315 are directed in conduit 760and split into two branches, 762A and 762B that lead up to the inlets712A and 712B of chambers 710A and 710B respectively. At the inlets, a2-way valve (V) or a gate value 764A, 764B regulates whether fluid willpass through one chamber or the other. In a preferred mode of operation,fluid 315 is run through only one chamber of the screening device 702 ata time. For example, fluid will be directed through the first chamber710A (with gate valve 764A open) while gate valve 764B will be closed).Once sump area 716A and first chamber 710A become filled with debris(D), the gate valves are reversed to permit fluid to be directed throughinlet 712B of the second chamber 710B. While fluid is passing throughthe second chamber 710B, the first chamber hatch 722A may be opened, andthe debris removed from sump area 716A. The screen 718A can also beremoved for cleaning, and then replaced to again make ready the firstchamber 710A. When second chamber 710B is filled with debris, the gatevalve 764A for the first chamber is opened, the gate valve 764B for thesecond chamber 710B is shut off, and the hatch 722 is opened to permitcleaning the debris our of sump collection area 716B, and cleaning ofscreen 718B. The screens 718 a, 718 b, 718-1, 718-2 can be configuredwith any desired mesh, sieve or screen perforations or openings 719 a,719 b sized based on the particle size permitted to pass through. In oneembodiment, the screen comprises a steel plate with desired perforationsdrilled or cut through.

As will be understood by those having the benefit of the presentdisclosure, the systems described herein can be used for variousseparation operations. For example, and without limitation, theseparation vessel 310 can be used to remove particulates, e.g.,suspended solids from water, as well as to remove colloidal materials(typically of a size of five micron and lower) or an LGS from a drillingfluid.

REFERENCES

The following represents an exemplary list of references.

U.S. Patent References

-   1. U.S. Pat. No. 5,741,426 McCabe et al.

All references referred to herein are incorporated herein by reference.While the apparatus and methods of this invention have been described interms of preferred embodiments, it will be apparent to those of skill inthe art that variations may be applied to the process and systemdescribed herein without departing from the concept and scope of theinvention. All such similar substitutes and modifications apparent tothose skilled in the art are deemed to be within the scope and conceptof the invention. Those skilled in the art will recognize that themethod and apparatus of the present invention has many applications, andthat the present invention is not limited to the representative examplesdisclosed herein. Moreover, the scope of the present invention coversconventionally known variations and modifications to the systemcomponents described herein, as would be known by those skilled in theart. While the apparatus and methods of this invention have beendescribed in terms of preferred or illustrative embodiments, it will beapparent to those of skill in the art that variations may be applied tothe process described herein without departing from the concept andscope of the invention. All such similar substitutes and modificationsapparent to those skilled in the art are deemed to be within the scopeand concept of the invention as it is set out in the following claims.

I claim:
 1. A solid-liquid separation apparatus for treatingcontaminated liquids contaminated with undesired solids and gasses,comprising: (a) an enclosed separation tower having an upper end and alower end opposite thereto, a longitudinal axis oriented substantiallyvertically through the upper end and the lower end, an outer wall, a topwall connected to the outer wall at the upper end and a bottom wallconnected to the outer wall opposite the top wall, the outer wall havingan inside surface and an outside surface; (b) a tower interior spacedefined as the space within the outer wall, top wall and bottom wall;(c) a contaminated liquids inlet located proximate the vessel lower endfor introducing the contaminated liquids into the tower interior space;(d) a clarified liquids outlet located above the contaminated liquidsinlet for discharging the clarified liquids to a desired location; (e) aplurality of baffle plates disposed in the tower interior space in aspaced apart relationship, with at least some of the baffle plates beingangularly disposed with respect to the longitudinal axis of theseparation tower to define a generally serpentine fluid flow passageway,the serpentine fluid passageway having a first end in fluidcommunication with the contaminated liquid inlet, and a second end influid communication with the clarified water outlet and the towerinterior space proximate the upper end of the tower, the angulardisposition of the plates creating a series of alternating downwardlyand upwardly sloped flow segments within the serpentine first fluid pathwherein the contaminated liquid generally flows downwardly in each ofthe downwardly sloped segments into a downward slope corner and upwardlyin the upwardly sloped segment toward an upward slope upper corner; (f)one or more solids discharge ports located in one or more of thedownward slope corners; (g) a standoff conduit in fluid communicationwith the one or more solids discharge ports for receiving solids fromthe contaminated water through the one or more solids discharge ports,the standoff conduit having at its lower end a solids outlet port; (h)one or more upper discharge slots located in one or more of the upwardslope upper corners; (i) one or more sources of vibrational energyapplied to the separation apparatus; and (j) one or more gas spargersmounted within said serpentine fluid passageway in an area above saidone or more solids discharge ports located in said one or more of thedownward slope corners for introducing a sparge gas into said serpentinefluid pathway.
 2. The solid-liquid separation apparatus of claim 1wherein said sparge gas is selected from the group consisting of air,inert gases, carbon dioxide, nitrogen, helium, and combinations thereof.3. The solid-liquid separation apparatus of claim 2 wherein the spargegas is carbon dioxide.
 4. The solid-liquid separation apparatus of claim1 further comprising a vacuum inlet in fluid communication with thetower interior space and located above the clarified liquid outlet forpulling a vacuum on the tower interior space to urge contaminated liquidinto the contaminated liquid inlet and up through the serpentine fluidflow passageway to the clarified liquid outlet; and a vacuumequalization conduit inlet in fluid communication with the towerinterior space and located above the clarified liquid outlet.
 5. Thesolid-liquid separation apparatus of claim 1 further comprising: one ormore electrocoagulation electrodes housed within said serpentine fluidpassageway capable of discharging an electrical current into the fluid,wherein said electrodes are capable of alternating between a positivepolarity and a negative polarity and are controlled by process controlequipment.
 6. The solid-liquid separation apparatus of claim 4 furthercomprising an oil accumulator for collecting oil, said accumulatorcomprising: an enclosed housing having a top, a bottom, sidewalls and aninner chamber, an accumulator oil inlet proximate or in said accumulatortop, said discharge tubing being connected between said accumulator oilinlet and said secondary standoff upper outlet, said discharge tubingplacing said accumulator inner chamber in fluid communication with saidsecondary standoff conduit, an accumulator vacuum inlet proximate saidaccumulator top, an accumulator vacuum equalizer conduit connectedbetween said accumulator vacuum inlet and said vacuum equalizationconduit inlet, said equalizer conduit placing said accumulator innerchamber in fluid communication with said tower interior space, an oiloutlet located in or proximate said accumulator bottom, an oil outletconduit connected to said oil outlet, an oil outlet control valveconnected to said oil outlet conduit for discharging oil from saidaccumulator through discharge conduit to a desired location, saidcontrol valve employing a one-way check valve on the discharge side ofsaid control valve, an upper liquid level control device within saidaccumulator inner chamber to sense the liquid level and communicate withsaid oil outlet control device, and a lower liquid level control devicewithin said accumulator inner chamber to sense the liquid level andcommunication with said oil outlet control device.
 7. The solid-liquidseparation apparatus of claim 1 further comprising a chemical injectionport for introducing into said serpentine fluid path one or more desiredtreatment chemicals.
 8. The solid-liquid separation apparatus of claim 7wherein said treatment chemical is a coagulant.
 9. The solid-liquidseparation apparatus of claim 1 further comprising: (k) one or moreelectrocoagulation electrodes housed within said serpentine fluidpassageway capable of discharging an electrical current into the fluid,wherein said electrodes are capable of alternating between a positivepolarity and a negative polarity and are controlled by process controlequipment; (l) a vacuum inlet in fluid communication with the towerinterior space and located above the clarified liquid outlet for pullinga vacuum on the tower interior space to urge contaminated liquid intothe contaminated liquid inlet and up through the serpentine fluid flowpassageway to the clarified liquid outlet; and a vacuum equalizationconduit inlet in fluid communication with the tower interior space andlocated above the clarified liquid outlet; and (m) a chemical injectionport for introducing into said serpentine fluid path one or more desiredtreatment chemicals.
 10. The solid-liquid separation apparatus of claim1 further comprising (k) a secondary standoff conduit, having upper andlower ends, in fluid communication with the one or more upper dischargeslots for receiving gasses, oils, bubbles and other lighter materialsfrom the contaminated liquids through the one or more upper dischargeslots, the secondary standoff conduit having at its lower end a loweroutlet for discharging accumulated solids, and having housed within itsupper end an upper outlet coupled with a weir for receiving oil anddischarging oil out the outlet into discharge tubing, the upper end ofthe secondary standoff conduit being in fluid communication with thetower interior space.
 11. A method of removing undesirable solids andgasses from liquid contaminants comprising the steps of: (a) directingthe contaminated liquids into the inlet of a solid-liquid separationapparatus for treating contaminated liquids contaminated with undesiredsolids and gasses, the apparatus comprising i. an enclosed separationtower having an upper end and a lower end opposite thereto, alongitudinal axis oriented substantially vertically through the upperend and the lower end, an outer wall, a top wall connected to the outerwall at the upper end and a bottom wall connected to the outer wallopposite the top wall, the outer wall having an inside surface and anoutside surface; ii. a tower interior space defined as the space withinthe outer wall, top wall and bottom wall; iii. a contaminated liquidsinlet located proximate the vessel lower end for introducing thecontaminated liquids into the tower interior space; iv. a clarifiedliquids outlet located above the contaminated liquids inlet fordischarging the clarified liquids to a desired location; v. a pluralityof baffle plates disposed in the tower interior space in a spaced apartrelationship, with at least some of the baffle plates being angularlydisposed with respect to the longitudinal axis of the separation towerto define a generally serpentine fluid flow passageway, the serpentinefluid passageway having a first end in fluid communication with thecontaminated liquid inlet, and a second end in fluid communication withthe clarified water outlet and the tower interior space proximate theupper end of the tower, the angular disposition of the plates creating aseries of alternating downwardly and upwardly sloped flow segmentswithin the serpentine first fluid path wherein the contaminated liquidgenerally flows downwardly in each of the downwardly sloped segmentsinto a downward slope corner and upwardly in the upwardly slopedsegment; vi. one or more solids discharge ports located in one or moreof the downward slope corners; vii. a standoff conduit in fluidcommunication with the one or more solids discharge ports for receivingsolids from the contaminated water through the one or more solidsdischarge ports, the standoff conduit having at its lower end a solidsoutlet port; viii. one or more sources of vibrational energy applied tothe separation apparatus; and ix. one or more gas spargers mountedwithin said serpentine fluid passageway in an area above said one ormore solids discharge ports located in said one or more of the downwardslope corners for introducing a sparge gas into said serpentine fluidpathway; (b) applying at least one vibrational energy source to theseparation apparatus; (c) introducing said sparge gas into saidserpentine fluid pathway; (d) flowing the solids laden liquids from theinlet upwardly through the generally serpentine fluid flow passageway tocause undesired solid materials striking the baffle plates to bedirected downwardly into the standoff conduit toward the lower end ofthe separation tower; (e) removing clarified liquid from the separationtower through the clarified water outlet, and (f) removing undesiredsolids from the standoff conduit.
 12. The method of claim 11 wherein thesolid-liquid separation apparatus further comprises: one or moreelectrocoagulation electrodes housed within said serpentine fluidpassageway capable of discharging an electrical current into the fluid,wherein said electrodes are capable of alternating between a positivepolarity and a negative polarity and are controlled by process controlequipment and said method further comprises the step of introducing acurrent from said electrodes into said serpentine fluid passageway, andalternating the polarity of said electrodes between positive andnegative polarity.
 13. The method of claim 11 wherein the solid-liquidseparation apparatus further comprises: a vacuum inlet in fluidcommunication with the tower interior space and located above theclarified liquid outlet for pulling a vacuum on the tower interior spacewith a vacuum apparatus to urge contaminated liquid into thecontaminated liquid inlet and up through the serpentine fluid flowpassageway to the clarified liquid outlet, and the method comprises theadditional step of applying a vacuum source at the vacuum inlet via thevacuum apparatus; removing undesired gasses out through the vacuumapparatus.
 14. A solid-liquid separation apparatus for treatingcontaminated liquids contaminated with undesired solids and gasses,comprising: (a) an enclosed separation tower having an upper end and alower end opposite thereto, a longitudinal axis oriented substantiallyvertically through the upper end and the lower end, an outer wall, a topwall connected to the outer wall at the upper end and a bottom wallconnected to the outer wall opposite the top wall, the outer wall havingan inside surface and an outside surface; (b) a tower interior spacedefined as the space within the outer wall, top wall and bottom wall;(c) a contaminated liquids inlet located proximate the vessel lower endfor introducing the contaminated liquids into the tower interior space;(d) a clarified liquids outlet located above the contaminated liquidsinlet for discharging the clarified liquids to a desired location; (e) aplurality of baffle plates disposed in the tower interior space in aspaced apart relationship, with at least some of the baffle plates beingangularly disposed with respect to the longitudinal axis of theseparation tower to define a generally serpentine fluid flow passageway,the serpentine fluid passageway having a first end in fluidcommunication with the contaminated liquid inlet, and a second end influid communication with the clarified water outlet and the towerinterior space proximate the upper end of the tower, the angulardisposition of the plates creating a series of alternating downwardlyand upwardly sloped flow segments within the serpentine first fluid pathwherein the contaminated liquid generally flows downwardly in each ofthe downwardly sloped segments into a downward slope corner and upwardlyin the upwardly sloped segment toward an upward slope upper corner; (f)one or more solids discharge ports located in one or more of thedownward slope corners; (g) a standoff conduit, having upper and lowerends, in fluid communication with the one or more solids discharge portsfor receiving solids from the contaminated water through the one or moresolids discharge ports, the standoff conduit having at its lower end asolids outlet port, and having its upper end in fluid communication withthe tower interior space; (h) one or more upper discharge slots locatedin one or more of the upward slope upper corners; (i) a secondarystandoff conduit, having upper and lower ends, in fluid communicationwith the one or more upper discharge slots for receiving gasses, oils,bubbles and other lighter materials from the contaminated liquidsthrough the one or more upper discharge slots, the secondary standoffconduit having at its lower end a lower outlet for dischargingaccumulated solids, and having housed within its upper end an upperoutlet coupled with a weir for receiving oil and discharging oil out theoutlet into discharge tubing, the upper end of the secondary standoffconduit being in fluid communication with the tower interior space; (j)one or more sources of vibrational energy applied to the separationapparatus; and (k) one or more gas spargers mounted within saidserpentine fluid passageway in an area above said one or more solidsdischarge ports located in said one or more of the downward slopecorners for introducing a sparge gas into said serpentine fluid pathway.15. The solid-liquid separation apparatus of claim 14 furthercomprising: (l) a vacuum inlet in fluid communication with the towerinterior space and located above the clarified liquid outlet for pullinga vacuum on the tower interior space to urge contaminated liquid intothe contaminated liquid inlet and up through the serpentine fluid flowpassageway to the clarified liquid outlet.
 16. The solid-liquidseparation apparatus of claim 14 further comprising: (l) one or moreelectrocoagulation electrodes housed within said serpentine fluidpassageway capable of discharging an electrical current into the fluid,wherein said electrodes are capable of alternating between a positivepolarity and a negative polarity and are controlled by process controlequipment.
 17. The solid-liquid separation apparatus of claim 14 furthercomprising a chemical injection port for introducing into saidserpentine fluid path one or more desired treatment chemicals.
 18. Amethod of separating contaminated liquids containing solids, water-basedliquids, oils and gasses from a mixed phase contaminated slurrycomprising the steps of: (a) directing the contaminated liquids into theinlet of a solid-liquid separation apparatus for treating contaminatedliquids contaminated with undesired solids and gasses, the apparatuscomprising: i. an enclosed separation tower having an upper end and alower end opposite thereto, a longitudinal axis oriented substantiallyvertically through the upper end and the lower end, an outer wall, a topwall connected to the outer wall at the upper end and a bottom wallconnected to the outer wall opposite the top wall, the outer wall havingan inside surface and an outside surface; ii. a tower interior spacedefined as the space within the outer wall, top wall and bottom wall;iii. a contaminated liquids inlet located proximate the vessel lower endfor introducing the contaminated liquids into the tower interior space;iv. a clarified liquids outlet located above the contaminated liquidsinlet for discharging the clarified liquids to a desired location; v. aplurality of baffle plates disposed in the tower interior space in aspaced apart relationship, with at least some of the baffle plates beingangularly disposed with respect to the longitudinal axis of theseparation tower to define a generally serpentine fluid flow passageway,vi. the serpentine fluid passageway having a first end in fluidcommunication with the contaminated liquid inlet, and a second end influid communication with the clarified water outlet and the towerinterior space proximate the upper end of the tower, vii. the angulardisposition of the plates creating a series of alternating downwardlyand upwardly sloped flow segments within the serpentine first fluid pathwherein the contaminated liquid generally flows downwardly in each ofthe downwardly sloped segments into a downward slope corner and upwardlyin the upwardly sloped segment toward an upward slope upper corner;viii. one or more solids discharge ports located in one or more of thedownward slope corners; ix. a standoff conduit, having upper and lowerends, in fluid communication with the one or more solids discharge portsfor receiving solids from the contaminated water through the one or moresolids discharge ports, the standoff conduit having at its lower end asolids outlet port, and having its upper end in fluid communication withthe tower interior space; x. one or more upper discharge slots locatedin one or more of the upward slope upper corners; xi. a secondarystandoff conduit, having upper and lower ends, in fluid communicationwith the one or more upper discharge slots for receiving gasses, oils,bubbles and other lighter materials from the contaminated liquidsthrough the one or more upper discharge slots, the secondary standoffconduit having at its lower end a lower outlet for dischargingaccumulated solids, and having housed within its upper end an upperoutlet coupled with a weir for receiving oil and discharging oil out theoutlet into discharge tubing, the upper end of the secondary standoffconduit being in fluid communication with the tower interior space; xii.one or more sources of vibrational energy applied to the separationapparatus; and xiii. one or more gas spargers mounted within saidserpentine fluid passageway in an area above said one or more solidsdischarge ports located in said one or more of the downward slopecorners for introducing a sparge gas into said serpentine fluid pathway;(b) applying at least one vibrational energy source to the separationapparatus; (c) introducing said sparge gas into said serpentine fluidpathway; (d) flowing the solids laden liquids from the inlet upwardlythrough the generally serpentine fluid flow passageway to causeundesired solid materials striking the baffle plates to be directeddownwardly into the standoff conduit toward the lower end of theseparation tower, and gasses, oils and light colloidal or suspendedsolids to be directed upwardly into the secondary standoff conduittoward the upper end of the separation tower; (e) removing clarifiedliquid from the separation tower through the clarified water outlet; (f)removing undesired solids from the standoff conduit; (g) removingundesired solids from the secondary standoff conduits; and (h) removingoils from the secondary standoff conduit.
 19. The method of claim 18wherein the solid-liquid separation apparatus further comprises a vacuuminlet in fluid communication with the tower interior space and locatedabove the clarified liquid outlet for pulling a vacuum on the towerinterior space to urge contaminated liquid into the contaminated liquidinlet and up through the serpentine fluid flow passageway to theclarified liquid outlet; and the method comprises the further steps ofapplying a vacuum source at the vacuum inlet via the vacuum apparatusand removing undesired gasses out through the vacuum apparatus.
 20. Themethod of claim 18 wherein the solid-liquid separation apparatus furthercomprises: one or more electrocoagulation electrodes housed within saidserpentine fluid passageway capable of discharging an electrical currentinto the fluid, wherein said electrodes are capable of alternatingbetween a positive polarity and a negative polarity and are controlledby process control equipment, and said method further comprises the stepof introducing a current from said electrodes into said serpentine fluidpassageway, and alternating the polarity of said electrodes betweenpositive and negative polarity.